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U: S~-3 8*0 . S~-3l<s-/ o 

DEPARTMENT OF THE ARMY TECHNICAL MANUAL | M 5"3o05"Zl U"l 

DEPARTMENT OF THE AIR FORCE TECHNICAL ORDER TO 




OPERATOR'S MANUAL 

GRADER, ROAD, MOTORIZED: 

DIESEL DRIVEN; 12,100 TO 14,300 LB 

PRESSURE AT BLADE; (HUBER-WARCO 

MODEL 4D) 

FSN 3805-542-2995 WINTERIZED 
FSN 3805-542-2996 NONWINTERIZED 



This copy is a reprint which includes current 
pages from Changes l and 4 



APARTMENTS OF THE ARMY AND THE AIR FORCE 

AUGUST 1962 



DEPARTMENT OF THE ARMY TECHNICAL MANUAL 
DEPARTMENT OF THE AIR FORCE TECHNICAL ORDER 



TM 5-3805-210-10 
TO 36C9-2-16-1 

C 1 



Operator's Manual 



GRADER, ROAD, MOTORIZED: DIESEL DRIVEN; 12,100 TO 14,300 
LB PRESSURE AT BLADE; (HUBER-WARCO MODEL 4D) FSN 3805-542-2995 
WINTERIZED FSN 3805-542-2996 NONWINTERIZED 



TM 5-3805-210-10 
TO 36C9-2-16-1 
CHANGES No. 1 



DEPARTMENTS OF THE ARMY 

AND THE AIR FORCE 
WASHINGTON 25, D. C., 5 April 1963 



TM 5-3805-210-10/TO 36C9-2-16-1, 7 August 1962, is changed as follows: 



Page 3, paragraph Id, lines 4 and 5. De- 
lete "Engineer Maintenance Center, ATTN: 
EMCDM-S," and substitute Mobility Support 
Center, ATTN: SMOMS-MS,. 

Paragraph 1. 

e. (Superseded) Report all equipment im- 
provement recommendations as prescribed by 
TM 38-750. 



Page 11, paragraph 7a. Delete "before start- 
ing engine" and substitute preventive mainte- 
nance. 

Page 20, paragraph 13a. (1). Delete "before- 
starting engine" and substitute preventive 
maintenance. 

Paragraph 14&. Delete "after-operation" 
and substitute preventive maintenance. 



Section III. PREVENTIVE MAINTENANCE SERVICES 

(Superseded) 



32. General 

(Superseded) 

To insure that the grader is ready for opera- 
tion at all times, it must be inspected system- 
atically, so that defects may be discovered and 
corrected before they result in serious damage 
or failure. The necessary Preventive Mainte- 
nance Services to be performed are listed and 
described in paragraph 33. The item numbers 
indicate the sequence of minimum inspection 
requirements. Defects discovered during opera- 
tion of the unit shall be noted for future cor- 
rection, to be made as soon as operation has 
ceased. Stop operation immediately if a de- 
ficiency is noted during operation which would 
damage the equipment if operation were con- 
tinued. All deficiencies and shortcomings will 
be recorded, together with the corrective action 



taken, on DA Form 2404 at the earliest possible 
opportunity. 

33. Daily Preventive Maintenance Services 

(Superseded) 

This paragraph contains an illustrated tabu- 
lated listing of preventive maintenance services 
which must be performed by the operator. The 
item numbers are listed consecutively and indi- 
cate the sequence of minimum requirements. 
Refer to figure 15 for the Daily Preventive 
Maintenance Services. 

Page 81, paragraph 5, line 1. Delete entirely. 

Page 84>, paragraph 3, lines 4 and 5. De- 
lete "Engineer Maintenance Center, ATTN: 
EMCDM-S," and substitute "Mobility Support 
Center, ATTN: SMOMS-MS/'. 



TAGO 8685A May 



PREVENTIVE MAINTENANCE SERVICES 

DAILY 



TM 5-3805-210-10 



ROAD GRADER 



HUBER-WARCO MODEL 4D 




ITEM 



LUBRICATE IN ACCORDANCE WITH CURRENT LUBRICATION ORDER 

PAR. REF 



MOLDBQARD, CUTTING EDGE, AND END BITS. Inspect for breaks 
and wear. Tighten loose mounting hardware. Replace cut- 
ting edge and end bits if worn within 3A inch of mold- 
board. (Biweekly) 



FIRE EXTINGUISHER. Check for broken seal. 



FUEL TANK, Check fuel level. 



RADIATOR. Check for proper coolant level. Proper coolant 
level is 1-1/2 inch below overflow pipe. 



BATTERIES. Check cables for loose connections. Check 
electrolyte level. Correct level is 3/8 inch above the 
plates. Do not add water in freezing weather unless 
engine i s to be operated immediately. (Weekly) 



AIR CLEANER AND PRECLEANER. Check oi 1 level. Add oi 1 to 
level mark. Clean precleaner before it is 3A full of 
dirt. (Biweekly) 



Figure 15. (Superseded) Daily preventive maintenance services. 



AGO 868J5A 



ITEM PAR. REF 


7 


FUEL FILTER. Inspect for leaks. Drain water and sediment. 




(Biweekly) 


8 


OIL LEVEL GAGE. Check oil level. Fill to FULL mark on 




gage. 


9 


INSTRUMENTS. Check for normal operation. Normal operat- 






ing readings for instruments should be as follows: Water 






temperature gage - 160 to 180F, Oil pressure gage - **0 






to 60 psi, Fuel pressure gage - RUN range, Ammeter - 






to 60+, Battery indicator - GREEN range, Tachometer - 






550 to 1,9^0 rpm as applicable. 





MSC 3805-210-10/15 



Figure 15 Continued. 



AGO 8685A 



By Order of the Secretaries of the Army and the Air Force: 



Official : 

J. C. LAMBERT, 

Major General, United States Army, 
The Adjutant General. 



EARLE G. WHEELER, 
General, United States Army, 
Chief of Staff. 



Official : 

R. J. PUGH, 

Colonel, United States Air Force, 

Director of Administrative Services. 

Distribution : 

Active Army: 

USASA (2) 

DCSLOG (1) 

CNGB (1) 

TSG (1) 

CofEngrs (3) 

CSigO (1) 

CofT (1) 

USA Maint Bd (1) 

USAARTYBD (2) 

USAARMBD (2) 

USAIB (2) 

USARADBD (2) 

USA Abn Elect & 
SPWAR Bd (2) 

USAAVNBD (2) 

USCONARC (3) 

USAMC (5) 

OS Maj Comd (5) except 
USARJ (10) 

MDW (1) 

Armies (2) 

Corps (2) 

USA Corps (1) 

Div (2) 

Eng-r Bde (1) 

USMA (2) 

Svc Colleges (2) 

Br Svc Sch (2) except 
USAES ( ) 

GENDEP (OS) (10) 
NG: State AG (3). 

USAR: Units same as Active Army 
For explanation of abbreviations used 



CURTIS E. LEMAY, 

Chief of Staff, United States Air Force. 



Engr Dep (OS) (10) 

Army Dep (2) 

USA Trans Tml Comd (2) 

Army Tml (1) 

USAOSA (2) 

Engr Dist (2) 

Div Engr (2) 

Engr Fid Maint Shops (2) 

USAERDL (3) 

Engr Cen (5) 

AMS (3) 

Chicago Engr Proc Ofc (10) 

USA Mbl Spt Cen (36) 

ESCO (10) 

Fid Comd, DASA (8) 

USACOMZEUR (2) 

USAREUR Engr Sup 

Con Agcy (10) 
USAREUR Engr Proc 

Cen (2) 
MAAG (1) 
JBUSMC (1) 
Units org under fol TOE : 
(2cyeaUNOINDC) 

5-5 

5-6 

5-15 

5-16 

5-35 

5-36 



5-38 

5-45 

5-46 

5-48 

5-54 

5-115 

5-117 

5-127 

5-145 

5-146 

5-155 

5-156 

5-237 (5) 

5-262 (5) 

5-267 (1) 

5-278 (5) 

5-279 

5-420 

5-425 

5-427 

5-500 (Tms EA, EB, HD, 

HE, HF, HG) 
5-600 
5-625 
5-627 
7-100 
17-100 
37-100 
39-51 
39-61 



except allowance is one copy to each unit. 
see AR 320-50. 



AGO 8685A 



Changes in Force: C 1 and C 4 



TM 5-3805-210-10 
TO 36C9-2-16-1 
*C4 



Change } 
No. 4 ( 



DEPARTMENTS OF THE ARMY 

AND THE AIR FORCE 
Washington, D. C., 17 July 1973 



Operator's Manual 

GRADER, ROAD, MOTORIZED: DIESEL DRIVEN; 
12,100 TO 14,300 LB. PRESSURE AT BLADE; 

(HUBER-WARCQ MODEL 4D) 

FSN 3805-542-2995 WINTERIZED 

FSN 3805-542-2996 NON-WINTERIZED 



TM 5-3805-210-10, 7 August 1962, is changed 
as follows: 

Page L In the table of contents, "I. REFER- 
ENCES" is changed to read "Appendix I. REF- 
ERENCES." 

Page 1. In the table of contents, "II. BASIC 
ISSUE ITEMS LIST" is changed to read "Appen- 
dix II. BASIC ISSUE ITEM LIST AND ITEMS 
TROOP INSTALLED OR AUTHORIZED." 
Page S. Subparagraph Irf is superseded as fol- 
lows: 

d. You can improve this manual by calling at- 
tention to errors and by recommending improve- 
ments, using DA Form 2028 (Recommended 
Changes to Publications), or by letter, and mail- 
ing directly to Commander, U.S. Army Troop 
Support Command, ATTN: AMSTS-MP, 4300 
Goodfellow Blvd., St. Louis, MO. 63120. 
Page 7. Subparagraph 46(14) is superseded as fol- 
lows: 

(14) Maintenance and Operating supplies. 
Refer to chart on pages 8 and 9 for a complete 
list of maintenance and operating supplies re- 
quired for initial operation. 

Page 22. In figure 5, callout 2 is superseded as 
follows: 

2. PLACE HAND THROTTLE IN CLOSED POSI- 
TION. 
Page 68. Paragraph 74 is superseded as follows: 

BMBonaa 

This change supersedes C 3, 2 April 1968. 



74. Service Brake Adjustment 

a. Minor Adjustment. The free brake pedal move- 
ment should be 3/4 to 1 inch (measured from 
pedal pad to bottom of floor plate) before plun- 
ger moves master cylinder piston. Perform the 
minor adjustment as follows: 

(1) Check the master cylinder fluid level (fill 
to 1/2 inch from top with an approved brake 
fluid). 

(2) Check pedal movement (3/4 to 1 inch). 

(3) Remove the adjustment hold covers on 
backing plates. 

(4) Expand brake shoes by turning adjusting 
screw until the shoe linings are against the drums. 

(5) Back the adjusting screw off three 
notches and replace the adjusting hole covers. 

NOTE 

If proper brake action is not obtained by 
minor adjustment perform the major ad- 
justment as described in b below. 
b. Major A djus tin en t. 

(1) Check fluid level. 

(2) Check pedal free travel. 

(3) Loosen lock nuts on anchor pins and 
move anchor pin until point of arrow faces cen- 
ter. 

(4) Move brake adjusting and feeler gage hole 
covers on backing plates. 



(5) Loosen lock nuts on centralizing bracket. 

(6) Turn adjusting screw until brake shoe lin- 
ings are expanded against the drums. 

(7) Tighten centralizing bracket locknuts. 

(8) Back off adjusting screw until a clearance 
of 0.014 inch is obtained between the bottom of 
the shoe linings and the drum. 

(9) Turn anchor pins in the reverse direction 
until a clearance of 0.008 inch is obtained be- 
tween the top of the lining and the drum. 

(10) Tighten anchor pin nuts. 

(11) Recheck bottom clearance for 0.014 
inch and readjust if necessary. 

(12) Tap backing plate with light hammer to 



insure the centralizer is taking the correct posi- 
tion between the shoe ends. 
(13) Replace all hole covers. 

NOTE 

Refer to figure 29 for service brake ad- 
justment. 

Page 69. In figure 29, Step 2 is superseded as 
follows: 

2. TURN ADJUSTING SCREW UP UNTIL 
BRAKE SHOES AND LININGS ARE EX- 
PANDED TIGHTLY AGAINST INSIDE OF 
BRAKE DRUM. TURN ADJUSTING SCREW 
DOWN THREE CLICKS. 
Page 83. Appendix II is superseded as follows: 



APPENDIX II 

BASIC ISSUE ITEM LIST AND ITEMS 
TROOP INSTALLED OR AUTHORIZED 

Section I. INTRODUCTION 



C-l. Scope 

This appendix lists basic issue items, items troop 
installed or authorized which accompany the 
grader and are required by the crew/operator for 
operation, installation, or operator's mainte- 
nance. 

C-2. General 

This basic issue items, items troop installed or 
authorized list is divided into the following sec- 
tions: 

a. Baric Issue Items List Section II. Not ap- 
plicable 

b. Items troop Installed or Authorized List- 
Section III. A list in alphabetical sequence of 
items which at the discretion of the unit com- 
mander may accompany the end item, but are 
NOT subject to be turned in with the end item. 

C-3. Explanation of Columns 

The following provides an explanation of col- 



umns in the tabular list of Basic Issue Items List, 
Section II, and Items Troop Installed or Au- 
thorized, Section III. 

a. Source, Maintenance, and Recover ability 
Code(S) (SMR): Not applicable. 

b. Federal Stock Number. This column indi- 
cates the Federal stock number assigned to the 
item and will be used for requisitioning purposes. 

c. Description. This column indicates the Fed- 
eral item name any additional description of the 
item required. 

d. Unit of Measure (U/M). A 2-character alpha- 
betic abbreviation indicating the amount or 
quantity of the item upon which the allowances 
are based e.g., ft, ea, pr, etc. 

e. Quantity Authorized (Items Troop Installed 
or Authorized Only). This column indicates the 
quantity of the item authorized to be used with 
the equipment. 



Section III. ITEMS TROOP INSTALLED OR AUTHORIZED LIST 



(1) 


(2) 


(3) 


<4l 


<5 




Federal 


Description 


Unit 


Qty auth 


SMR 


stock 


Ref.No.&Mfr Usable 


of 




code 


No. 


code on code 


meas 






4210-889-2221 


EXTINGUISHER, FIRE 


EA 


1 



By Order of the Secretaries of the Army and the Air Force: 



Official: 



CREIGHTON W. ABRAMS 
General, United States Army 
ChiefofStaff 



VERNE L. BOWERS 

Major General, United States Army 

The Adjutant General 



Official: 



JOHN D. RYAN, General USAF 
ChiefofStaff 



DWIGHTW.COVELL,Co&meJ, USAF 
Direc tor of A dminis tra tion 



Distribution: 

To be distributed in accordance with DA Form 12-25B (qty rqr block No. 393) Operator's Maintenance requirements for 
Graders. 



This manual contains copyright material 

*TM 5-3805-210-1 0/TO 36C9-2-16-1 

TECHNICAL MANUAL v DEPARTMENTS OF THE ARMY 

No. 5-3805-210-10 / n TH An 

TECHNICAL ORDER f AND THE AI 

No. 36C9-2-16-1 ) WASHINGTON 25, B.C., 7 

OPERATOR'S MANUAL 
GRADER, ROAD, MOTORIZED: DIESEL DRIVEN; 12,100 TO 14,300 

LB PRESSURE AT BLADE; (HUBER-WARCO MODEL 4D) 

FSN 3805-542-2995 WINTERIZED FSN 3805-542-2996 

NONWINTERIZED 

Paragraph PIRC 

CHAPTER 1. INTRODUCTION 

Section I. General - 1, 2 3 

II. Description and data 3-5 3 

CHAPTER 2. INSTALLATION AND OPERATION INSTRUCTIONS 

Section I. Service upon receipt of equipment 6-9 11 

II. Controls and instruments 10, 11 11 

III. Operation of equipment 12-21 20 

IV. Operation of auxiliary materiel used in conjunction with the equipment 22-27 31 

CHAPTER 3. MAINTENANCE INSTRUCTIONS 

Section I. Operator's tools and equipment 28, 29 35 

II. Lubrication 30, 31 35 

III. Preventive maintenance 32,33 51 

IV. Troubleshooting- 34-49 54 

V. Field expedient repairs 50-53 55 

VI. Fuel system 54-58 55 

VII. Cooling system 59-61 59 

VIII. Electrical system 62-66 62 

IX. Clutch release mechanism and brake 67-69 65 

X. Handbrake 70, 71 68 

XL Service brake system 72-74 68 

XII. Hydraulic system 75, 76 70 

XIII. Windshield wiper assemblies 77,78 72 

XIV. Scarifier assembly 79-81 72 

XV. Moldboard assembly 82-84 73 

XVI. Winterization equipment 85-87 76 

CHAPTER 4. DEMOLITION OF MATERIEL TO PREVENT ENEMY USE 88-92 79 

I. REFERENCES 81 

II. BASIC ISSUE ITEMS LIST 83 

INDEX 87 



"This manual supersedes TM 5-3805-210-10, 4 May 1960, including C 1, 9 October 1961, and C 2, 10 January 
1962. 



TM 5-~3805--2!0--10/rO 36C9-2-16-1 



CHAPTER 1 
INTRODUCTION 



Section I. GENERAL 



1. Scope 

a. These instructions are published for the 
use of the personnel to whom the Huber-Warco 
Model 4D Grader is issued. They provide in- 
formation on the operation, lubrication, and 
preventive maintenance services of the equip- 
ment, accessories, components, and attach- 
ments. 

b. Appendix I contains a list of applicable 
publications. Appendix II contains a list of the 
basic issue items authorized for use by the oper- 
ator. The maintenance allocation chart is lo- 
cated in TM 5-3805-210-20. 

c. Numbers in parentheses on illustrations 
indicate quantity. Numbers preceding nomen- 
clature callouts on illustrations indicate the pre- 
ferred maintenance sequence. 



d. Report all deficiencies in this manual on 
DA Form 2028. Submit recommendations for 
changes, additions, or deletions to the Com- 
manding Officer, U.S. Army Engineer Mainte- 
nance Center, ATTN: EMCDM-S, P.O. Box 
119, Columbus 16 Ohio. Direct communication 
is authorized. 

e. Report unsatisfactory equipment perform- 
ance and suggestions for equipment improve- 
ment to the organizational unit for initiating 
necessary corrective action. 

2. Record and Report Forms 

For record and report forms applicable to the 
operator, refer to TM 38-750. 

Note. Applicable forms, excluding standard Form 
46 which is carried by the operator, shall be kept in 
a canvas bag mounted on the equipment. 



Section II. DESCRIPTION AND DATA 



3. Description 

The Huber-Warco Model 4D is a 6 wheel, 
pneumatic-tired road grader. It is driven by a 
4-cylinder diesel engine and is equipped with 
two chain drive assemblies which transmit 
power to the tandem drive wheels. The chain 
drives are located in the tandem drive cases 
(fig. 1) and operate in oil. The grader is 
equipped with a hydraulic control system which 
receives its power from an engine-mounted hy- 
draulic pump. The hydraulic control levers are 
located on the dash directly in front of the 
operator's seat and control the operation of the 
circle side shift cylinder (fig. 1) and the blade 
lift cylinders (fig. 2), circle reverse assembly, 
leaning wheel tie bar, and the scarifier lift cyl- 
inder. The grader is equipped with a 12-foot 



moldboard assembly and an eleven-tooth scari- 
fier assembly. The grader has two independent 
brake systems. One brake system is hydraulical- 
ly controlled and operated by a foot pedal; the 
other brake system is mechanically controlled 
by a hand lever. The grader is equipped with a 
five-speed transmission, four forward speeds 
and one reverse. An overdrive transfer lever al- 
lows the operator to select a high or low speed 
range in any one of the forward or reverse 
gears. The grader is equipped with a 24-volt 
electrical system which consists of four 12-volt 
batteries connected in series parallel, a genera- 
tor, voltage regulator, and starter. 

4. Identification and Tabulated Data 

a. Identification. The road grader has ten 
identification plates. 



TM 5-3805-2 10-10/TO 36C9-2-16-1 



r 




i 



1 



TM 5-3805-210-10/TO 36C9-2-16-1 




i 






TM. 3~3i0S-210-~1/TO 36C9-2-16-1 



(1) Corps of Engineers unit identification 
plate. Located on the left side of the 
frame above the front axle. Specifies 
the nomenclature, Federal stock num- 
ber, manufacturer, model, date manu- 
factured, serial number, contract num- 
ber, and USA registration number. 
Also specifies make, model, and serial 
number of the engine. 

(2) Corps of Engineers scarifier data 
plate. Located on the left side of the 
scarifier arm. Specifies the nomencla- 
ture, make, model, serial number, and 
date of manufacture. Also specifies 
the nomenclature, make, model, and 
Federal stock number of the road 
grader. 

(3) Hydraulic lift cylinder caution plate. 
Located on the inside of the cab to the 
right of the operator's seat. Specifies 
precautions to be observed when side- 
shifting the circle and drawbar to 
maximum right or left and when rais- 
ing the blade lift cylinders with the 
blade in the right- or left-hand ditch- 
ing position. 

(4) Engine data plate. Located on the 
left side of the engine on the rocker 
arm cover. Specifies the model, unit 
serial number, and maximum revolu- 
tions per minute of the engine with 
no load. 

(5) Gearshift diagram plate. Located on 
the right side of the dash panel. Il- 
lustrates the shifting positions of the 
transmission gearshift lever and 
transfer drive gearshift lever. 

(6) Winterization control schematic dia- 
gram plate. Located on the inside of 
the cab to the left of the operator's 
seat. Illustrates a complete schematic 
diagram of the winterization system. 

(7) Air cleaner instruction plate. Located 
on the outer oil cup of the air cleaner. 
Gives instructions and intervals for 
servicing the air cleaner. Also gives 
manufacturer's name, 

(8) Lifting attachment capacities plate. 
Located to the rear of, and beside the 
transportation data plate. Specifies 
the lifting capacities in pounds of the 



lifting eyes located on the front and 
rear of the grader. 

(9) Transportation data plata. Located 
on the lower-left side panel of the 
operator's cab. Specifies the overall 
length, height, and width of the 
grader. Also specifies the height re- 
ducible to, shipping cubage, shipping 
weight, and shipping tonnage of the 
grader with and without a cab. 
(10) Transmission data plate. Located on 
the left-front side of the transmission 
case. Specifies the make, specification 
number, and serial number of the 
transmission. 
b. Tabulated Data. 

(1) Road grader. 

Manufacturer .. Huber-Warco Co. 

Model 4D 

Serial number range: 

Winterized MD-101W thru MD-125W, 

and MD-810W thru MD- 
829W 

Nonwinterized MD-126 thru MIX-806, and 

MID-830 thru MD-1107 

(2) Engine. 

Manufacturer , Detroit Diesel Engine Div, 

of General Motors Corp. 

Model ...4025 

Type ^ . Diesel two cycle 

Cylinders 4 

Compression ratio 17 to 1 

Firing order 1-3-4-2 

'Maximum rpm no load 1,940 rpm (revolutions per 

minute) 

(3) Engine air cleaner. 

Manufacturer Nichols Mtetals Mfg. Co., 

Inc. 

Model _ A-12509 

Type Oil bath 

(4) Engine coolant heater. 
Manufacturer Perfection Industries, Div, 

of Hupp Corp. 

Model . MH-60-D1 

Capacity 60,000 Btu (British thermal 

units) per hour. 
Voltage 24 

(5) Space heater. 

Manufacturer Perfection Industries, Ddv. 

of Hupp Corp. 

Model _MH-30-B-2 

Capacity 30,000 Btu per hr 

Voltage 24 

(6) Primary fuel filters. 

Manufacturer AC Division of General Mo- 
tors Corp. 



TM 5-3805-2 10-10/TO 



Model -------------------- TU60 

Element type ------------- Disposable 

(7) Secondary fuel filter. 

Manufacturer ------------ AC Division of General Mo- 

tors Corp. 
Model ------------------- T-58 

Element type . ------- ......Disposable 

(8) Primary oil filter. 

Manufacturer ------------ AC Division of General Mo- 

to** 8 Cor P- 
Model ----------------- 5193258 

Element type __. ---- ....Disposable 

(9) Batteries. 

Volts -------------------- 12 

Type -------------------- ;6TN 

Number required --------- 4 

(10) Tires. 

Size --------------------- 113.00 x 24. 

Ply ______________________ 8 

Pressure ----------------- 25 psi (pounds per square 

inch) '(increase tire pres- 
sure 25% for mainte- 
nance work on established 
highways). 

(11) Capacities. 

Fuel tank ________________ 50 gal (gallons) 

U Jt 

Air cleaner ___ Jl~~4-i/2 qt 
Transmission _____________ 48 qt 

Transfer drive ----------- 6 qt 



Tandem drive case ________ 28 qt ea (each) 

Circle reverse case ________ 3 qt 

Steering gear ____________ 1 qt 

Hydraulic system _________ 30 gal 

Hydraulic tank ___________ 16-1/2 gal 

Hydraulic brake system. ___ 1 pt (pint) 

(12) Adjustment data. 

Fan, water pump, and 1/2 in. (inches) deflection 
generator belts. between pulleys. 

(13) Dimensions and weights. 
Overall length ____________ 311 in. 

Overall width ____________ 96 in. 

Overall height with cab r ..127 in. 
Overall height without 111 in. 

cab. 
Height reducible to _______ 93 in. 

Shipping cubage with cab ..2,167 cu ft (cubic feet) 
Shipping cubage without 1,860 cu ft 

cab. 
Shipping tonnage with 54 tons 

cab. 
Shipping tonnage without 47 tons 

cab. 

Shipping weight with cab ..25,180 Ib (pounds) 
Shipping weight without 24,780 Ib 

cab. 

(14) Maintenance and operating supplies. 
Refer to chart below for a complete 
list of maintenance and operating sup- 
plies required for initial operation. 



TM 5-3805-210-10/TO 36C9-2-16-1 







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TM 5-3805-21 0-1 0/TO 36C9-2-16-1 

5. Difference in Models 

This manual covers the Huber-Warco Model 
4D motorized road grader, winterized and non- 
winterized. The winterized serial number range 
is MD-101W through MD-125W and MD- 
810 through MD-829. The nonwinterized serial 
number range is MD-126 through MD-806 
and MD-830 through MD-1107. Machines in 
serial range MD-810 through MD-1107 have 
been improved over machines in serial range 
MD-101W through MD-806 W as follows: oil 
level plugs in the transfer case, transmission, 
and tandem drive have been replaced with dip- 
sticks. All standard plugs have been replaced 
with magnetic plugs and gaskets. A guide and 
adapter have been utilized to receive &n ex- 
tended crankcase oil level gage, which permits 



the operator to check the crankcase oil level 
with the side panel in place. Three ether start- 
ing aids are used in place of the one previously 
used. The instrument panel has been revised 
and contains a horn button. A tachometer, cali- 
brated from to 2,500 rpm, is located in the 
center of the instrument panel. The coolant 
temperature gage is graduated from 120 to 
240. The oil pressure gage id graduated from 
to 120 psi, A horn button is located on the 
right side of the instrument panel. The posi- 
tion of all switches and gages has been changed; 
all switches with exception of the instrument 
panel light switch are grouped in the lower, 
left corner. All gages are located on the slope 
of the instrument panel in full view of the op- 
erator. The ammeter has been replaced by a 
battery indicator gage. 



TO 



TM 5-3M5-210-10/TO 3*Ct-2~.!*~1 



CHAPTER 2 
INSTALLATION AND OPERATION INSTRUCTIONS 



Section I. SERVICE UPON RECEIPT OF EQUIPMENT 



6. Unloading The Rood Grader 

The operator of the road grader may assist in 
unloading the equipment from the common 
carrier. The operator will help remove tie-down 
cables, strapping, blocking, and the like which 
secure the equipment. The operator will drive 
the road grader down the ramp when hoisting 
equipment is not available, using the following 
procedures: 

a. Start the engine (par. 18). 

b. Run the machine on the flatcar until it 
is in alinement with the ramp. 

c. Test brakes before approaching ramp. 
Warning. 9 Be sure the flatcar is blocked so 

it cannot move. 

7. Inspecting and Servicing The Road Grader 

Note. Make sure the road grader is completely de- 
procesaed before servicing. Make sure preservatives 
have been removed from such items as the crankcase, 
transmission, transfer case, air cleaner, tandem drive 
housings, fuel tanks, hydraulic tanks, and gearcases. 

a. Perform the before starting engine serv* 
ices listed in paragraph 33. 



6. Inspect to see that the required tools, re- 
pair parts, publications, accessories, and at- 
tachments are with the road grader. 

c. Inspect the road grader for loss of parts 
or damage which may have occurred during 
loading, removal, or shipment. 

d. Report all damage or deficiencies to or- 
ganizational maintenance. 

8. Installation or Setting-up Instructions 

A bolt (fig. 2) is -installed in the leaning 
wheel tie bar to secure the tie bar to the front 
axle during shipment; this maintains the front 
wheels in the vertical position. Remove this bolt 
before putting the road grader into operation. 
No further installation or setting-up instruc- 
tions are required to prepare the road grader 
for operation. 

9. Movement to a New Work Site 

The road grader can be moved to a new work 
site under its own power or hauled by common 
carrier. No disassembly is required for move- 
ment to a new work site. 



Section II. CONTROLS AND INSTRUMENTS 



10. General 

This section describes, locates, illustrates, 
and furnishes the operator, crew, or driver 
sufficient information about the various con- 
trols and instruments for proper operation of 
the road grader. 



1 1 . Controls and Instruments 

The purpose and normal reading of all con- 
trols and instruments are illustrated on figure 
3. 



11 



TM 5-3805-210-10/TO 36C9-2-16-1 



TROUBLE LIGHT RECEPTACLE: 
USED AS SOURCE OF 
FOR TROUBLE LIGHT. 



INSTRUMENT PANEL LAMP 
SWITCH: TURNS PANEL 
LAMP ON AND OFF. 



FLOODLIGHT SWITCH: TURNS,, 
FLOODLIGHT OH OR OFF* I 




^'' "C-VT 
i****l2 t " 

WATER TEMPERS HJlVf 
GAGE; INDICATES 
WATER TFMPt.RATl'f<T, 
NORMAL 
18QF, ' 

BY 

i "'HI 






/'V'lM^i, If , i 







12 



.- Engine instrument panel (Serial range MD-101W through MD-806) 
Figure 3. Controls and instruments. 



TM 5-3805-2 10-10/TO 36C9-2-16-1 



OIL PRESSURE GAGE: 
INDICATES ENGINE OIL 
PRESSURE; NORMAL. 
READING 40-60 PSI. 



INSTRUMENT PANEL 
LIGHT; ILLUMINATES 

INSTRUMENT PANEL, 



AMMETER: INDICATES 
GENERATOR CHARGING 
RATE; NORMAL READING 
0-60^ 



IEADL1GHT AND Bl ..... ACK- 

F LIGHT SWITCH: 
TURNS HE AD 1 ...... 1GHTS OR 



HOURMETER: 

INDICATES HOURS 
OF OPERATION,, 

I 

IGNITION AND START 
SWITCH: TURNS ON 
IGNITION AMD ACTIVATES 
STARTER. 



BLACKOUT LIGHTS 



R E A R W ! N D S H I E i D W I P E R S W ! T C 1 i 

TURNS WINDS! t!Ei D WIPER ON 



FRONT WiNDSHiEi WIPER SWITCH: 

TURNS WiNDSHiEi WIPER ON OR OFF, 



805-210-10/3 (2 




B Engine instrument panel (Serial range MD-101W through MD-806) 
Figure 3 Continued. 



TM 5-380S-110-10/TO 



FUEL PRESSURE GAG! 
INDICATES FUEL 
PRESSURE; NORMAL 
READING M 



WATER TEMPERATURE GAGE: 
INDICATES WATER TEMPERATURE; 
i NORMAL READING I60-18CTF. 



"' A I H l ' 1NDICA1CP: 
V. INI MCA If '^BATTERY 

-O /r.T,F ; NORMAL 
Af/Ni', GREEN, 



TAOHCA/CTPP; 
INDiCATfS F.NGIfJf- 

PF'V AND RECORDS 
HOURS OF OPERATION; 



OIL PRESSURE GAGE: 
INDICATES ENGINE OIL 
PRESSURE; NORMAL 
READING 40-60 PS I. 



f I OGIM IGHT WITCH- 

rn/ouLiGi 

AMI; 




14 



C Engine instrument -panel (Serial range MD-810W through MD-1107) 
Figure S Continued. 



TM $-3805-210-10/1 36C9-2-16-1 



PANE'L 

LIGHT: ILLUMINATES 
INSTRUMENT PANEL, 



run LI vn t 



HORN SWITCH: 
ACTIVATES 



! FVf L MOF^MALLY 

IN f Ul L POSITION, 



H: TURNS 
IfcS STARTER 



AO ?XJT LKiHT SWITCr 
1 ; BLACKOUT LIGhlS 
ON Aflf' Off . 




EMC 3805-210-10/3(3) ' 



D Engine instrument panel (Serial range MD-810W through MD-U07) 

Figure 3 Continued. 



15 



TM 5-3805-210-10/TO 36C9-2-16-1 



FRONT WHEEL LEAH CONTROL 
LEVER: LEANS FRONT WHEELS 



_. , _.,__ 
LEFT HAND BLADE CONTROL LEVER: T0 R|GHT OR , EFT 



RA1SES AND LOWERS LEFT 
END OF BLADE. 



CIRCLE SIDE SHIFT CONTROL LEVER: 
MOVES BLADE AND CIRCLE ASSEMBLY 
TO RIGHT OR LEFT. 



RIGHT HAND BLADE CONTROL , 
LEVER: RAISES AND LOWERS 
RIGHT FMD OF BLADE, 




TPANSFLR DRIVE GEARSHIFT 



SCARIFIER CONTROL LEVER: 
RAISES AND LOWERS SCARIFIER. 



CIRCLE TURN CONTROL 
LEVER: TURNS CIRCLE 
ASSEMBLY RIGHT OR LEFT, 



L VFR- SHIFTS TRANSFER ? 

INTO HIGH OR LOW 
f-ANGE AND NEUTRAL, 



HANDBRAKE LEVFR 
FNCAGES PARKING 
BRAKE* 



THROTTLE CONTROL: 
CONTROLS THE SPEED 
OF IHf ENGINE, 



STEERING WHEEL: TURNS 
FRONT WHEELS TO RIGHT 
OR LEFT, 



BRAKE PEDAL: 
tNGAGFS BRAKES, 



CLUTCH PEDAL: EHGAGLS 
AMD DISENGAGES THE 
FMU1NE CLUrCH. 



* f ' "* ifi* "%""*""""' ...... TH k *j "* 

> J.A 
l.l 



, , r 
IF i ' f CROSS SH1F I 1N[ t X PIN 




r rpr/;s SHIF 

IM AN 'i' JM' CJ THREC 

P'" n /r-N 







16 



E Operator's control levers and pedals 
Figure 3 Continued. 



TM 5-3805-2 10- 1 0/TO 36C9-2-16*-! 



* , - 

CAB HEATER THERMOSTAT CONTROt - 

CONTROLS THE TRMPL-PA IhJRF OF 
: THE OPERATORS CAB AOJf/3T/fU i 
BETWEEN 50 AND IOC n * . 



FRONT L TAN- 
ING WHt LL 

CONTROL 
LEVfR 



CIRCLE TURN 
CONTROL 




'' r i i /" i 
-dp?-" \j? / 



fMERGfcNCY SHUTOFF CONTROL; ShUTS 
OFF FNGiNE IN CMERGFNCY; NORMALLY 

IN. PULL TO STOP ENGINL. 



LEFT DOOR 
C/EFPOSTrP 







I; 




RADIATOR 
/TIER 



NO 



IATOR SH ; ..... n ...... r L : R ADJUST ING i, FVE.- R: 

iNS AND Ci ..... CSLS RADIATOR SHi ..... r] ..... [T'R, 
MAi ...... \ ...... V OPEN. 




H 



EMC 3805-2)0-10/2 0) 



F Cab heater thermostat control G Emergency shutoff control H Radiator shutter adjustment 

Figure S Continued. 17 



TM S~3i0J-210--10/T0 



HFATEP CONTROL BOX 
H 



l^ttx, 




.' HEATER IS IN OPERATION, ALSO 
{,, USED TO CHECK HEATER WIPING 
III CIRCUIT. 

m 



hiAFF? SWITCH: TURNS H'fATFR TO*" " 

"OH Hi", "ON LO" AND "OFF" POSITIONS, 




18 



I-Cab heater control box J-Battery and engine heater control boxes 

Figure 5 -Continued. 



TM 5-3805-2 10-10/TO 36C92~16~! 



ENGINE FUEL PRIMING PUMP: 
PUMPS FUEL FROM THE PRIMARY 
FUEL FILTER INTO THE INJECTION 
MANIFOLD TO AID IN STARTING 
THE ENGINE. 



// 



ENGINE 

OIL FILLER CAP 




K Priming pump, hydraulic oil filter, and slave receptacle 
Figure 8 Continued. 



TM 5-3805-210-10/10 36C9-2-16-1 



Stetson HI. OPERATION OF EQUIPMENT 



12. General 

#. The instructions in this section are pub- 
lished for the information and guidance of the 
personnel responsible for operation of the 
road grader. 

b. The operator must know how to perform 
every operation of which the road grader is 
capable. This section gives instructions on 
starting and stopping the road grader, basic 
motions of the road grader, and instructions on 
coordinating the basic motions to perform the 
specific tasks for which the . equipment is de- 
signed. Since nearly every job presents a differ- 
ent problem, the operator may have to vary 
given procedures to fit the individual job 

1 3. Starting The Road Grader Engine 

a. Preparation fonBtarting. 

(1) Perform the before-starting engine 
services { par. 33). 

(2) Lubricate the road grader as specmed 
in the current lubrication order (LO 
5-3805-210-20). 

b. Starting the Engine. Start the engine as 
instructed on figure 4. 

1 4. Stopping The Road Grader Engine 

a. Stop the engine as instructed on figure 5. 
6. Perform the after-operation services (par. 
33). 

1 5. Road Grader Operation 

a. General The road grader is used in the 
construction and maintenance of roads, general 
grading, and snow removal. The raising, low- 
ering, tilting, and side-shifting of the blade, 
and raising and lowering of the scarifier can be 
accomplished by the operator while the grader 
is in motion. 

b. Operating the Road Grader. 

( 1 ) Start the engine ( par. 13 ). 

(2) Operate the road grader as instructed 
on figure 6. 

c. Earthworking Operation. The various 
earthworking operations of which the road 
grader is capable are illustrated on figure 7. 



16. Operation in Extreme Cold (Below 0F.) 

a. See that antifreeze solution has been 
checked and is correct for the lowest possible 
temperature expected. 

b. Inspect cooling system and report any 

leaks. 

c. Keep batteries fully charged. After adding 
water, run engine at least one hour. 

d. Keep fuel tank full at all times to prevent 
condensation. 

e. Drain and service fuel filters frequently 
(par. 57 and 58). 

/. Use the engine coolant heater and battery 
heater to warm the engine oil, coolant, and bat- 
teries before starting engine. Allow engine to 
warm up before applying load. 

g. Lubricate as specified in the current lu- 
brication order (LO 5-3805-210-20). 

1 7. Operation in Extreme Heat 

a. Cooling. Inspect radiator core frequently 
to make it clean and free of obstructions. 

6. Grader. Inspect instruments and gages 
frequently to make sure grader is not being 
overloaded. Reduce depth of cut if necessary. 

c. Lubrication. Check oil levels frequently 
as extreme heat may cause excessive oil con- 
sumption. 

1 8. Operation in Dusty or Sandy Areas 

a. Fuel. Strain fuel before adding to fuel 
tank. Prevent sand from entering fuel while 
pouring. Service air cleaner frequently to re- 
move sand and dust. 

b. Lubrication. Clean all lubrication points 
before applying lubricants. Clean areas around 
oil filler cap and oil level gage before inspect- 
ing or adding engine oil (par. 31). 

c. Protection. Protect the grader when not 
in operation by covering with tarpaulins and 
taking advantage of natural barriers to prevent 
dust and sand from entering components of the 
grader. 

19. Operation Under Rainy or Humid 
Conditions 

If unit is outside and not operating, protect 
it with a canvas or other waterproof cover. Re- 
move cover during dry periods. Open housing 



TM 5-3805-21 0-10/TO 36C9-2-16-1 




1. ENGAGE HANDBRAKE. 



2. DEPRESS CLUTCH AND PLACE GEARSHIFT LEVERS 
IN NEUTRAL POSITION. 





PLACE HAND THROTTLE CONTROL IN 
ONE-HALF ENGINE SPEED POSITION. 



NOTE: 



DO NOT ENGAGE THE STARTING 
MOTOR FOR MORE THAN 30 SECONDS 
AT ONE TIME. EXCESSIVE HEAT MAY 
DAMAGE THE STARTING MOTOR. 



4, TURN IGNITION KEY TO THE START 
POSITION. RELEASE KEY WHEN 
ENGINE STARTS. 

5. WHEN ENGINE STARTS PLACE THE 
THROTTLE CONTROL IN JUST ABOVE 
IDLE POSITION AND PLACE THE 
TRANSFER GEAR SHIFT LEVER IN 
FORWARD OR REVERSE POSITION. 
ALLOW ENGINE TO WARM UP BEFORE 
PUTTING GRADER IN OPERATION. 



NOTE: 



DO NOT LEAVE THE TRANSFER GEAR 
SHIFT LEVER IN THE NEUTRAL POSITION FOR 
MORE THAN A FEW MOMENTS. THE TRANSFER 
DRIVE INPUT SHAFT BEARINGS DO NOT 
RECEIVE LUBRICATION IN THE NEUTRAL 
POSITION. 



EMC 3805-210-10/4 



Figure 4* Starting the road grader engine. 



TM 5-3805-2 10-10/TO 36C9-2-16-1 




Figure 5. Stopping the road grader engine. 



22 



TM 5-3805-210-10/TO 




A Putting grader in motion 
Figure 6. Road grader operation. 



TM 5-3805-21 0-10/TO 36C9-2-16-1 



_ . 

PULL TO RIGHT TND o MO? r 

PUSH TO 



L M. *Ml*ffiWt/A^W 



PULL TO RAISE LEFT END OF MOL PROAS! >; 
PUSH TO LOWER, {fe 

^ II 





EMC 3805-2 10-10/6' 



B Moldboard operation 
Figure 6 -Continued. 



TM 5-3805-210-10/TO 36C9-2-16-1 



PUSH TO LOWER SCARIFIER; 
PULL TO' RAISE. 




SCAWFM.K 



6-2 1 0-10/6 



C Scarifier operation 
Figure 6 Continued 



25 



TM 5-3805-210-10/TO 36C9-2-16-1 



TO TURN TO 

PULL TO TURN CIRCLE TO LEFT, 



CIRCLE TURN ASSFMBLV 



" 




D Circle turn operation 
Figure 6 Continued. 



TM 5-3805-2 10-10/T 36Cf-2-16-t 



TO TO 

PULL TO TO LEFT 



PROMT LEANING WHEELS 




E Front wheel leaning operation 
Figure 6 Continued. 



27 



TM 5-3M5-210-10/TO 36C9--3-16-1 



TO SHIFT CIRCLE TO RIO! fl 

PULL TO SHIFT CiRCl F TO I..FF-T 




F Circle side shift operation 
Figure 6 Continued. 



28 



TM S-3WS-210-10/TO 36C9-2-16- 






,EMC 3805-210-10/7 (] 



A-Cutting action B-Starting the ditch C-Ditching in reverse 

Figure 7. Earthworking operations. 



TM S~3i05.--210.-10/TO 36C9-2-16-1 




D Moving the windrow 



30 



E Sloping low banks 
Figure 7 Continued. 



EMC 3805-210-10/7 

F Sloping high banks 



TM 5-380S-2 10-10/T 36C9 2 16 1 



access doors to allow unit to dry out before op- 
erating 1 . Keep fuel tanks-full to avoid conden- 
sation. 

20. Operation In Salt-Wafer Aireas 

a. General. Wash the grader frequently with 
clean, fresh water. Do not contaminate fuel 
system or damage electrical system. 

b. Protection. Coat exposed metal surfaces 
with rustproof ing material. Remove rust im- 
mediately and apply paint and/or oil as appli- 
cable. 

c. Cooling. Be sure water used in cooling 
system is free of salt and alkali. 

Caution: The cooling system is not intended 
for iise with salt water; however, salt water 
may be used in an emergency. 



21 . Operation at High Altitudes 

a. The grader is designed to operate at ele- 
vations up to 5,000 feet above sea level with- 
out special service or adjustment. 

b. Above 5,000 feet, the grader capacity will 
be reduced. This is a normal condition which 
cannot be prevented, but maximum perform- 
ance can be maintained by following all service 
instructions carefully. Be sure air cleaners are 
clekn and free of objects that might restrict 
the flow of air to the engine. 

Note. Less air is drawn into the cylinders at high 
altitudes, which results in a richer fuel mixture, in- 
complete combustion, and a reduction of power. Horse- 
power decreases as altitude increases. 



Section IV. OPERATION OF AUXILIARY MATERIEL USED IN 
CONJUNCTION WITH THE EQUIPMENT 



22. Fire Extinguisher (Monobromofriftuoro- 
methone Type) 

a. Description. The monobromotrifluorome- 
thane type fire extinguisher replaces the carbon 
dioxide and carbon tetrachloride type fire ex- 
tinguishers used in the past. It is generally 
suitable for use on all types of fire, with excep- 
tion of fires involving LOX (liquid oxygen) 
generating equipment. The fire extinguisher is 
{furnished with a disposable type cylinder. 

5. Operation. To operate the fire extin- 
guisher, perform the following operations : 

(1) Remove fire extinguisher from its lo- 
cation. 

(2) Break the seal by pulling the safety 
pin from the handle. 

(3) Point the horn at the base of the 
flame. 

(4) Depress trigger for discharge and 
direct the stream of contents at the 
base of the fire. 

Warning: Avoid breathing of 
smoke. 

(5) Replace with new cylinder immediate- 
ly after using. 

c. Replacement of Cylinder. To replace with 
new cylinder, perform the following operations: 
(1) Press lever to release pressure from 
old cylinder. 



(2) Loosen swivel valve coupling nut and 
remove the valve assembly from used 
cylinder. 

(3) Remove instruction band from used 
cylinder. 

(4) Place new cylinder through the in- 
struction band. 

(5) Replace safety pin in valve and seal 
pin with seal wire. 

(6) Attach valve assembly and tighten 
swivel coupling nut on the new cyl- 
inder; replace fire extinguisher in 
mounting bracket. 

(7) Adjust instruction band on cylinder 
to show maintenance and operating 
instructions. 

d. Maintenance. Weigh fire extinguisher 
every 6 months and replace cylinder if gross 
weight has decreased 4 ounces or more. Lubri- 
cate cylinder neck threads with one drop of OE 
30 oil before reassembly. 

23. Fire Extinguisher (Carbon Dioxide Type) 

a. Description. The carbon dioxide fire ex- 
tinguisher is suitable for use on electrical and 
flammable liquid fires. The carbon dioxide 
types are of 4-pound, 7-1/2 pound, and 10- 
pound sizes. The 4-pound extinguisher is port- 
able; the other two are fixed on the equipment. 



TM 5-3805-2 10-10/TO 36C9-2-16-1 

6. Operation. Remove the fire extinguisher, 
break the seal, operate the control valve, and 
direct the stream at the base of the flame. 

c. Refilling and Maintenance. Refer to TM 
9-1799 and TM 5-687 for refilling and main- 
tenance instructions for the carbon dioxide fire 
extinguisher. 

24. Slave Receptacle 

a. Description. The slave receptacle is 
mounted on the left side of the engine housing 
below the fuel tank. The receptacle leads are 
connected to be battery side of the starter 
solenoid and ground. The receptacle is used as 
a connection to start the engine from an exter- 
nal power source when the grader batteries are 
discharged. 

b. Operation. Operate the slave receptacle as 
instructed on figure 8. 

25. Heaters 

a. Description. The heater controls are lo- 
cated in the operator's cab. The space heater 
control box is mounted on the right side of the 



cab dash panel." The engine coolant and battery 
heater control boxes are mounted to the right 
of the operator's seat. The space heater heats 
the operator's cab and is thermostatically con- 
trolled by a thermostat assembly located on the 
cab dash panel. The operator can set the ther- 
mostat to any temperature between 50 and 
100F. The engine heater is used to warm the 
engine coolant, and the exhaust from the heater 
is used to heat the lubricating oil to aid in 
starting the engine in cold weather. The battery 
heater heats the battery compartment to pro- 
vide peak battery output for starting the en- 
gine in cold weather. 
b. Operation. 

(1) Close the radiator shutters. 

(2) Open the heater fuel shutoff valves. 

(3) Operate the space, engine, and battery 
heater as instructed on figure 9. 

Caution: Never attempt to start the 
heaters while the lamp indicator is on. 

26. Ether Starting Aids 

a. Description. Three ether starting aids are 
located in the operator's cab to the left of the 







Figure 8. Slave receptacle operation. 



32 



TM 5-3805-21 0-1 0/TO 36C9-2-16-1 



. PLACE SWITCH IN "ON H1 M 
OR "ON LO" POSITION, 
7 f ~ 



1. Ff I " fhSl LCHi IF * f H 
in" hi -LOWS, !rli 

* ' "* COM! Itri K 



CAB HEATER CONTROL PANE! 



?>,'( , NOT 

Nf MI BUTTON. 



NOTE: 1HI 




WHEN HFA1ER 
/'* ,' TP b TURNED 
<* 

i 






<,iNfc COO! AN! Hf AH ' 



BAI iU<' /'?//' f ill / M I ' ' ' II ' 

115,71 / 



<V 



,,,,,, 




A Space heater control panel B Battery and engine heater control panels 

Figure 9. Space, engine, and battery heater operation. 



33 



TM 5--3805-210-10/TO 36C9-2-16-1 

operator's seat. Ether capsules are inserted in 
the starting aids to facilitate starting the en- 
gine. In temperatures above 0F., the engine 
can normally be started with one starting aid. 
In temperatures of 0F. to -65F., it may be 
necessary to use all three starting aids simul- 
taneously. 

6. Operation. Operate the ether starting 
aids as instructed on figure 10. 



27. Trouble Light 

The trouble light is located in the toolbox 
under the right side of the operator's seat. 
When its use is required, remove the light from 
the toolbox and the shield from the trouble 
light socket (A fig. 3). Push the connector end 
of the light cord into the socket and turn 
clockwise until locked in position. 



V INSTALL CAP AND PUSH DOWN CAPSULE PIERCING 
STARTER SWITCH AND START ENGINE, 



L ' CAP* 



CAPSULE PIERCING 
LEVER 




ETHER 
CAPSULE, 



4. REMOVE CAPSULE AFTER ENGINE 
!S STARTED AND REPLACE CAP, 

OPERATE REMAINING STARTING AIDS IN THE SAM? 'MANNFR. 

EMC '3805-?! 0-10/10 



Figure 10. Ether starting aid operation. 



34 



TM 5-3805-2 10-10/T 36C9-2~16-1 



CHAPTER 3 
MAINTENANCE INSTRUCTIONS 



Section I. OPERATOR'S TOOLS AND EQUIPMENT 



28. Special Tools and Equipment 

No special tools or equipment is needed by 
the operator for the maintenance of this road 
grader. 



29. Basic issue Tools and Equipment 

Tools and repair parts issued with or author- 
ized for the road grader are listed in appendix 
II. 



Section II. LUBRICATION 



30. General Lubrication Information 

a. This section contains lubrication instruc- 
tions which are supplemental to, and not speci- 
fically covered in, the lubrication order (fig. 
11). 

b. The lubrication order shown in figure 11 
is an exact reproduction of the approved lubri- 
cation order for the road grader. For current 
lubrication order, refer to DA Pam 310-4. 

31 . Detailed Lubrication Information 

a. Care of Lubricants and Lubricating Equip- 
ment. Keep all lubricants in closed containers 
and stored in a clean, dry area away from heat. 
Do not allow dirt, dust, water, or other foreign 
material to come in contact with lubricants. 
Keep lubricating equipment clean and filled 
for immediate use. 

b. Cleaning. 

(1) Wipe grease fittings with a clean, dry 
cloth before lubricating. Remove oil 
or hardened lubricants from fittings 
with an approved cleaning solvent. 

(2) Keep areas around drains, filler caps, 
and plugs clean. Remove caps or plugs 
only when checking levels or adding 
lubricants. 

(3) After lubrication, wipe excess lubri- 
cant from fittings. 



c. Lubrication. 

(1) Lubricate in the proper quantity. Re- 
fer to the current lubrication order for 
capacities. 

(2) Apply grease to fittings until it is 
visible from the part being lubricated 
unless otherwise specified. Use cau- 
tion when lubricating parts containing 
seals; excessive pressure may ruin 
seals. 

d. Points of Application. Points requiring 
lubrication are illustrated as reference views 
on figure 11. 

e. OESOil 

(1) The crankcase oil level must be 
checked frequently as oil consumption 
may increase, 

(2) The oil may require changing fre- 
quently because contamination by di- 
lution and sludge formation will in- 
crease during cold-weather operation. 

/. Primary and Secondary Oil Filter Service. 
Service the primary and secondary filters as in- 
structed on figure 12. 

g. Transmission Breather Service. Service 
the- transmission breather as instructed on fig- 
ure 13. 

h. Air Cleaner and Precleaner Service. Serv- 
ice the air cleaner and precleaner as instructed 
on figure 14. 



TM 5-3805-210-10/TO 36C9-2-16-1 



LUBRICATION 
ORDER 

LC 36C9-M6-1 





,Y 1962 Sup.rede? LO 5-3805-210-2Q.1/LC 34C9-M6-1. 21 Octob.r 1960) 



GRADER, ROAD, MOTORIZED: DIESEL DRIVEN; 12,1OO 
TO 14,300 LB PRESSURE AT BLADE; (HUBER- 
WARCO MODEL 4DJ W/GMC DIESEL ENGINE 
MODEL 4025 

Reference: LO 5-3805-210-20-2. SM 10-1-C4-1 



intervals are based on normal hours of operation. Reduce to 
compensate for abnormal operations and severe conditions. Dur- 
ing inactive periods, sufficient lubrication must be performed 

for adequate preservation. 

Clean fittings before lubricating. 
Relubricate after washing or fording. 
A dotted circle indicates a drain below. 



Clean parts with SOLVENT, dry-cleaning, or with OIL, fuel, 
Diesel. Dry before lubricating. 

Lubricate points indicated by dotted arrow shafts on both sides 
of equipment. 

Drain gearcases when hot. Fill and check level. 




-Pintle Hook 
(2 fittings.) 

-Tandem Case Drain Plug 
(Drain and refill.) 
-Final Drive Drain Plug 
(Drain and refill.) 
-Final Drive Carrier Bearing GAA 
-Transmission and Final @0 
Drive Fill Plug (See key.) 
Gear Shift and Rod Bearing GAA 
^Transmission Drain Plug 
(Remove and clean plug.) 
(Drain and refill.) 
' Tandem Case Bearings GAA 

(2 fittings.) 
-Clutch Release Bearing GAA 

(See note 6.) 

-Throttle Control Cable GAA 
-Transfer Case Fill GO 

(See key.) 
-Hydraulic System Fill and 2135H 
^FilterfSee key.) (See note 3.) 
-Gear Shift and Rod Bearing GAA 

(4 fittings.) 

-Steering Wheel Bracket GAA 
-Steering Universal Joints GAA 
-Scarifier Lift Shaft Bearing GAA 
-Steering Universal Joint GAA 
-Tie Rod Pivot GAA 
(3 fittings.) 



IUS8ICANT e INTERVAL 



GAA 



INTERVAL LUBRICANT 



-Leaning Wheel Tie Rod Pivot 
" '" "-King Pin 

(Upper and lower fitting.) 
-Leaning Wheel Pivot 



GAA 
GAA 

GAA 
GAA 





Tandem Case Bearings 
(2 fittings.) 
Tandem Case Fi 
and Dipstick (Check level.) 
(See key.) (See note 5.) 
Tandem Case Level Plug- 
(Check level.) (See note 5.) 
Transmission Breather- 
(Clean and re-oil.) 
Transmission and Final Drive- 
Level Plug or Dipstick (Check 
level.) (See note 5.) 
Transfer Case Level Plug- 
or Dipstick (Check level.) 
(See note 5.) 
Clutch Brake Shaft Bearings - 
Tandem Cose Drain Plug- 
(Drain and refill.) 
Transfer Case Drain Plug- 
(Drain and refill.) 
Hydraulic System Drain Plug- 
(Drain and refill.) 
Saddle Bushings 
(Upper and lower fitting.) 
Side Shift Arm Bearing - 
Circle Gearcase Level Plug- 
(Check level.) (See note 5.) 
Circle Gearcase Fill and- 
Dipstick (See key.) 
(Check level.) (See note 5.) 
Circle Gearcase Drain 
(Drain and refill.) 
Circle Gearcase Bearing - 
Steering Drag Link Bearings- 
Steering Cylinder Bearings* 

3805-2lO-"Wn " 




36 



Front 
Figure 11. Lubrication nrder. 



TM 5-3805-210-10/TO 36C9-2-16 1 




H CONTINUED PROM. 



LUBRICANT INTIRVAl 



^PRECEDING PAGE 



INTERVAL ' LUBRICANT 



Transfer Shift Bearing 
Overdrive Lever 
-Throttle Control Cable AA 
Index Pin Cable A A 



Index Pin Right Side AA 

Side SHift Cylinder AA 

Ball Joint 

Index Pin Cylinder Of 



Index Pin Cable 
Scarifier Lift Link 
Steering Gear Housing 
Level Plug 
(Check level.) 
: ront Wheel Bearings 
(Sparingly.) 



Drawbar Boll Socket OAA 




Brake Pedal- 

Clutch Pedal" 

Brake Master Cylinder 1 

Fill and Level Plug 

(Check level.) (See key.) 

Orel 



OAA 



10 GAA 



(Clean and coot.) (See note 4.) 

Lift Cylinder Pivot 

(3 fittings.) 

Drawbar Lift Cylind 

Index Pin Left Side 

Scarifier Cylindei 

Steering Gear Housing Fill 

(See key.) 

Steering Gear Housing Drai 

(Remove capscrew on 

plate at input shaft. J 

Front Axle Pivot- 




-KEY- 



LUftRICANTS 


CAPACITY 


EXPECTED TEMPERATURES 


INTERVALS 


Above +32F 


+40F to-10F 


0F to-65F 


GO-LUBRICANT, Gear Universal 




GO 140 


GO 90 


GOS 


Intervals given 
are in hours of 
normal operation. 


Transmission and Final Drive 


48 qt 


Transfer Drive 


6qt 


Tandem Case 


28 qt ea 


00 90 


Circle Gearcase 


3qt 


GO 140 


Steering Gear Housing 


Iqt 


0OS-LUBRICANT, Gear Universal; Sub-zero 





2135'H-LUBRICATING OIL. Hydraulic 




2135-H 


2110-H 


2075- H 




Hydraulic System 


120qt. 


HB -HYDRAULIC Fl.uid, Non-petroleum 




All Temperatures 


Brake Master Cylinder 


Kqt 


OE-OIL, Engine, Heavy Duty 




Oil Can Points. 




GAA-GREASE, Automotive and Artillery 





NOTES: 

l.FOR OPERATION OF EQUIPMENT IN PROTRACTED COLD 
TEMPERATURES BELOW -10F. Remove lubricants prescribed 
in the key for temperatures above -10F. Clean parts with SOL- 
VENT, dry-cleaning. Relubricate with lubricants specified in 
the key for temperatures below -10F. 

2. OIL CAN POINTS. Every 50 hours lubricate all controls, 
levers, linkage, stop cable, and all exposed adjusting threads 
withOE. 

3. HYDRAULIC SYSTEM. Every 10 hours clean filter by 
turning handle one complete turn with engine operating. Every 
2000 hours drain system by removing hose connections or drain 
plug at bottom of tank. Remove filter from tank, clean element 
and sump. Install filter and hose connections or drain plug. Fill 
system, operate engine and controls 5 minutes, check level, 
and bring to 3 inches from top of tank. 

4. GRADER CIRCLE. Do not lubricate turn. pinion teeth or gear 
teeth of circle. 

5. GEARCASE OIL LEVEL. Dipstick ued on units after serial 
number MD810, level plugs before. 

6. CLUTCH RELEASE BEARING. Every 5 hours lubricate 
clutch release bearing if excessive clutching is necessary in 



grader operation. Force approximately /4 oz lubricant into bear- 
ing while rotating. CAUTION: Be sure transmission is in neu- 
tral. Rotate bearing By depressing clutch pedal to eliminate 
free travel with engine running. Do not over lubricate. NOTE: 
Every 250 hours remove transmission adapter housing cover, 
inspect hose, and remove excessive lubricant. 



BY ORDER OF THE SECRETARIES OF THE ARMY AND THE 
AIR FORCE: 

G.H. DECKER, 
General, United States Army, 



OFFICIAL: 

J.C.LAMBERT, 

Major General, United States Army, 
The Adjutant General. 



OFFICIAL: 

J.L.TARR, 

Colonel, United States Air Force, 
Director of Administrative Services. 



Chief of Staff. 



THOMAS D. WHITE, 

Chief of Staff, 
United States Air Force. 



EMC 3805-210-10/11 

EMC 5-3805-210-10/1 



Back 
Fiaure 11 Continued. 



37 



5-3805-21 0-1 0/TO 36C9-2-16-1 



LUBRICATION 
ORDER 

LC 36C9-2-16-2 




16 FEBRUARY 1960 



GRADER, ROAD 9 MOTORIZED; DIESEL DRIVEN; 12,100 TO 

14,3OO LB PRESSURE AT BLADE: 12 FT BLADE 

(HUBER-WARCO MODEL 4D) W/GMC 

DIESEL ENGINE MODEL 4O25 

Reference: LO 5-3805-210-20-1, SM 10-1-C4-1 



Intervals are based on normal hours of operations. Reduce to 
compensate for abnormal operations and severe conditions. Dur- 
ing inactive periods sufficient lubrication must be performed for 
adequate preservation. 

Clean fittings before lubricating. 
Relubricote after washing or fording. 



A dotted circle indicates a drain below. 

Clean parts with SOLVENT, dry-cleaning, or with OIL, fuel, 
Diesel. Dry before lubricating. 

Drain crankcase only when hot after operation; replenish and 
check level when cool. 



LUBRICANT INTERVAL 



INTERVAL LUBRICANT 



OE 



65 






- Crankcase Fill 
(See key) 

-Starter Bearings OE 



(Remove plugs, lubricate 
sparingly, install plugs) 

-Crankcose Oil Level Gage 
(Check level) 




OE 



Precleaner and Sight Glass - 
(Remove cleone- when dirt 
collects at sight glass. 
Wash, dry and install) 

Air Cle 



(Check Uvel. Every 50 
operating hours disassemble, 
clean, and re-oil) (See key) 



OAA Fan Hub Bearing - 



100 



ENGINE (LEFT SIDE) 



(Remove plug, install 
fitting, lubricate, remove 
fitting and re-install plug) 
Water Pump 
(Prepacked bearings 
no lubrication required) 

Engine Oil Filter 

(See note 3) 



CONTINUE DON 
FOLLOWING PAGE 



EMC 3805-21 0-1 0/11 C 3 _> 



Front (Engine, left side) 
Figure 11 Continued. 



TM 5-3805-210-10/TO 36C9-2-16 



LUBRICANT INTERVAL 



CONTINUED FROM 
PRECEDING PAGE 



INTERVAL e LUBRICANT 



Generator Bearings 
(Sealed bearings, no 
lubrication required) 




100 



Engine Oil Pilfer 
(See note 3) 



Engine Oil Pilter Drain 

Plug 

(Drain onaVtefill 

through crahkcase) 

Crankcase Drain Plug 
(Drain and refill) 




ENGINE (RIGHT SIDE) 



-KEY- 



LUBRICANTS 


CAPACITY 


EXPECTED TEMPERATURE 


INTERVALS 


Above +3TF 


+40*Fto.10rF 


0*F to -65*F 


OE-CIL, Engine, Heavy Duty 




OE 30 
or 
9250 


OE 10 
or 
9110 


OES 


"Intervals given 
are in hours of 
normal operation" 


Air Cleaner 


4ttt. 


Crankcase 


18qts. 


OES-OIL, Engine, Sub-zero 




GAA-GREASE, Automotive and Artillery 




All Temperatures 



NOTES: 

1. FOR OPERATION OF EQUIPMENT IN PROTRACTED COLD 
TEMPERATURES BELOW -10*F. Remove lubricants prescribed 
in the key for temperatures above -KTF. Clean parts with SOL- 
VENT, dry-cleaning. Relubricote with lubricants specified in 
the key for temperatures below -10*F. 

2. OIL CAN POINTS. Every 50 service hours, lubricate gover- 
nor and throttle control linkage, clevis and pivot points with 

3. ENGINE OIL FILTERS. Every 100 service hours, or at crank- 
case oil change, remove filter element, c(ean falter housing and 
install new filter element. Fill crankcase, operate engine 5 min- 
utes, chectuhousing and lines for leaks. Check crankcase level 
and bring to full mark. 



Copy of this Lubrication Order will remain with equipment at 
all times; instructions contained herein are mandatory. 



BY O4NMB Of TWS UCMTABIM Of TNI AKMY AMD TNI AIR POtCI: 



4 Shtfvt Army. 
~ 



L L UMMITXII, 
J, UnitaN< SloteJ Armr, 
CfeW f $I8. 



THOMAS 0. WHITS, 
CkM ot Mad, 



EMC 3805-21 0-1 0/11 ( 



Rear (Engine, right side) 
Figure 11< Continued. 



TM 5-3805-210-10/10 36C9-2-16-1 



REF. K PINT! E 





REF, 2. TAHDEW i ASh n 
RLF, 30. TANDEM C A >tf ;' 



K UG 




'M 





, 



'/tv 




40 



References 1 through 7, 27, 28, 30, and 31 
Figure 11 Continued. 



j' ^i L ^ 6* ft F^ 1 U 

t 'x^i,' >p 4/*i. f H1VL 

7 '* rn/ * nr K 

- jt i VT? PLUG 

/ ! /"< A IU F f l UG 

1 / ' i(J6 ^10 JO' 11(5) 



TM 5-3805-210-10/10 36C92-16 1 




REF. 6. TANDEM CASE BEARINGS 
REF. 23. TANDEM CASE BEARINGS 

REF. 24,, TANDEM CASE FILL AND 
DIPSTICK 



7^ 





REF. 9. CLUTCH RELEASE 
BEARING 



f?/ ' 1( ' Him/Hi fc roHUVOL CABLE 





REF. 12. HYDRAULIC SYSTEM FILL 
AND FILTER 




References 5 through 12, .23, 24, and 41 
Figure 11 Continued. 



TM 5-3805-210-10/TO 




* 13, GEAR SHIFT AMD ROD 




REF. 13, GFAf? SHIFT AND TOO I" 

RET, 42, OVEpDRIVK LCVtR 

REF, 53 BRAKE PCDAL 

RET, S4 C";iJl | C H 




WMLCL SHACKfiT 
MI'iP', i, STITfcufNG UfVEM';,]/'L JOfNTf 
Pi.if'% ifc, THRO'JTU'; CURIUM CABLf: 



R E F , *: 0, o C A R I F ! E F ,! , ' t >\ 





7, ( > J It" i H i M,i '/ M | y/ L i f 'a ^ / j < I 




42 



References 13 through 17, 42, 43, 49, 50, 53, 54, and 60 through 62 
Figure 11 Continued. 



TM 5-3M5-210-10/TO 36C9- < 2-16-1 




* UE AN we WHEEL ^ Ptycrr 
r" w "is* 'STEERING DRAG UN^ 
,' 40* 





<.BEF W 19* LEANING WHEEL TIE ROD PIVOT 
REF. 20. KING PIN 
REF, 22 V LEANING WHEEL CYLINDER' ' 




Rf% 22, LEANING WHEEL 
, 63* FRONT AXLE PIVOT 



REF, 25* TANDEM CASE L 
PLUG 




* 1 . 26, TRANSMISSION BREATHER 




R E F , 



9, C i U T C H D R / K < , f f f, v 7 
B TARINGS 



EMC 3805-210-10.. 



References 18 through 22, 25, 26, 29, 39, 40, and 63 
Figure 11 Continued. 



43 



TM 



5-3805-210-10/TO 36C9-2-16-1 




DRAIN "UJU 






References 32 through 40, 44, 45, 59, and 60 
Figure 11 Continued. 



TM S-4MS-210-10/TD 




REF* 44. NDEX>|N CABLE 




4ft, SHIFT CYLINDER 

BALI, JOINT 

.REF* 56, CIRCLE 




PF.F. 47. IMOtx PIN ("YliNflFR 
EK, 48, !Nl)f-X Hf4 'VAtll f 




49. SCARIFIER LIFT LINK 




. 51. FRONT WHEEL BEARINGS 




f. 52 DRAWBAR BALL SOCKET 



EMC 3805-2IO-10/li"8 



References 44, 46, through 49, 51, 52, and 56 
Figure JJf Continued. 



TM 



53805 210 tO/?O 36C9 2 16 1 




PILL AND LEVEL PLUG 




CYLINDER PIVOT 




LIFT CYLINDER 





REF. ""64. CRANKCASE FILL 
REF 65. STARTER BEARINGS 

REF. 66 CRANKCASE OIL 

LEVEL GAGE 



46 




AND 
SIGHT GLASS 



REF. 88, AIR CLEANER 



__ . Q-' 



References 515, 57, 58, and 68 through 68 
Figure 11 Continued. 



TM 5-3805-21 0-1 0/TO 36C9-2-I6-1 




i 

REK. 69, FAN HUB 




F , 7C,, ENGtNL ofi FtLTfcR 




/ "G2NE Oil, FtJ TEF? 

' ) AIN 




References 69 through 73 
Figure 11 Continued. 



TM 5-3805-21 0-1 0/TO 36C9-2-16-1 






2 CENTER STUD AND 

THE GIL PiLltK 
SHFLL, ELtMEKT ^ND GASKfcl. 



CLEANING - 
Will- A .. ILL'.'. ' 
INSTALL 




2 I OOSEH CENTER. STUD 
RFMfiVE SHELL EtEMf 
ANt- GASKET, 

3 CLEAN SHf.LL ^TlH AN APPFGV 
CLEANING MM... VENT &NJ INSTAL 
WITH A HtW ELEMENT AND uAj, 
INSTALL DWAiN PLUG, 




EMC 3805-?! 0-10/1 2 



A Primary oil filter 



B Secondary oil filter 



Figure It. Primary and secondary oil filter service. 



t 



TM S 3805 210 10/TO 36C9 2 16 1 



:, u LAN B*- 

PP^OVf i< CLEAN! 








Figure 1$. Transmission breather service. 



TM 5-3805~210-I0/TO 36C9-2-16-1 



AIR 

CLEANtR 

F VECVEANEP- 



AIR CLEANER 



1 , rxvi-^% tflNGNl/7 

Af/; REMOVE THE AIR 
il. CUP 




; rL;.,u^^m!0'^ikx^ 



4.. LOOSEN WING NUT 
AND DISASSEMBLE 



COVER 





A Air cleaner service 
B Precleaner service 

Figure 14. Air cleaner and precleaner service. 



"t 380^2 10- 1 0/1 4 



50 



TM S-ii05-210-!0/T 36C9-2-16-1 



Sscfbn 111. PREVENTIVE MAINTENANCE 



32. General 

To insure that the equipment is ready for 
operation at all times, it must be inspected sys- 
tematically before operation, during operation, 
and after operation, so that defects may be 
discovered and corrected before they result in 
serious damage or failure. The necessary pre- 
ventive maintenance services will be per- 
formed before operation. Defects discovered 
during operation of the unit will be noted for 
future correction, to be made as soon as oper- 
ation has ceased. Stop operation immediately 
if a deficiency is noticed during operation 
which would damage the equipment if opera- 
tion were continued. After-operation services 
will be performed by the operator after every 
operating period. After-operation services will 
be performed at intervals based on the normal 
operations of the equipment. Reduce interval 
to compensate for abnormal conditions. Re- 
sponsibility for performance of preventive 
maintenance services rests not only with the 
operator but also with the entire chain of com- 
mand from section chief to commanding offi- 
cer (AR 750-5). 

Note. Record all uncorrected deficiencies on DA 
Form 2404. 

33. Daily Maintenance Service and 
Inspection Procedures 

a. General. The specific daily inspections 
and services that are to be performed by the 
operator or crew are listed below as items 1 
through 13 and are to be performed at indi- 
cated intervals. 

6. Specific Service and Inspection Instruc- 
tions. Specific service and inspection instruc- 
tions are contained in the appropriate refer- 
enced paragraphs below and on figure 15. The 
illustrated inspection and service intervals are 
indicated by -an "X" in the appropriate block 
on each illustration as follows: 
B Before operation 
D During operation 
A After operation 

Note. Detailed instructions for the applicable main- 
tenance, service, and inspection procedures are ref- 
erenced by the paragraph numbers listed. 



Paragraph 

Before Starting Engine 

1 Visual inspection. Make general in- 

spection of the entire unit for cracks, 
breaks, loose or missing bolts and 
nuts. Check tire inflation. Normal 
tire pressure is 25 psi. 

2 Cutting edges, end bits, and scarifier S3 1 

teeth. Inspect these items for wear, 
damage, and missing parts. Replace 
or turn cutting edges or end bits 
damaged or worn beyond acceptable 
standards. Replace or turn cutting 
edge when worn beyond 3/4 inch of 
moldboard. 

8 Cooling system, engine crankcase oil 60, 61, 
level, fan belts, and generator belts. 63 
Check coolant level. When filling the 
radiator with antifreeze, allow room 
for expansion and run engine long 
enough to mix the solution thorough- 
ly. Check fan and generator belts for 
condition and adjustment. Belt deflec- 
tion is 1/2 to 3/4 inch midway be- 
tween pulleys. 

4 Check fire extinguisher for condition, 

sufficient charge, and secure mount- 
ing. Check fuel tank level, hydraulic 
supply tank level, final drive, trans- 
mission transfer case, and tandem 
drive lubricating oil levels. Check the 
battery cables for tightness of mount- 
ing and electrolyte level. The electro- 
lyte level should be 3/8 inch above the 
plates. Check winterization equipment 
for proper operation and leaks. 

5 Tools and equipment. Check all tools 

and equipment assigned to the grader, 
making sure they are serviceable, 
clean, and properly stowed or 
mounted. 

Start 'Engine 

6 With engine running, listen for an> 

unusual noises. Check all gages and 
instruments for proper operation. 
Check engine clutch and brake for 
proper operation. 

During Operation 

7 Engine. During operation listen for 

any unusual noises and note if there 
is any indication of loss of power 
while engine is under load. Look for 
excessive black or blue smoke from 
exhaust pipe. 

8 Check all forward and reverse speed 

ranges, noticing if all shifts are 
smooth and without excessive vibra- 
tion or unusual noises. Notice if 



fl 



TM 5-3805-210-IO/TO 36C9-2-16-I 

item During operation Continued "aragraph. Item 

clutch is not releasing properly or slip- 10 

ping and if brakes are grabbing 1 or 
dragging. Check steering mechanism 
and all operating controls for prop- 
er operation. 

9 Check all instruments, gages, switches, n 

lights, and horn for proper operation. 
Notice if working lights are properly 
aimed and securely mounted. At nor- 
mal operating speed, the gage read- 
ings should be as follows: Oil pres- 12 
sure 40-60 psi, water temperature 
160F-180F., ammeter in the charge 
range, and fuel pressure in the run 13 
range. 



During operation Continued 

Temperatures. Check transmission and 
tandem drive for excessive heat. An 
overheated gear housing indicates in- 
ternal maladjustment, damage, or in- 
adequate lubrication. 

After Operation 

Leaks. Inspect all drive gearcases and 
housings for leaks. Pay particular 
attention to engine cooling system, lu- 
brications, and fuel and hydraulic 
line connections. 

Inspect identification and instruction 
plates, paint, and marking for condi- 
tion and secure mounting. 

Service and lubricate in accordance 
with LO 5-38^5-210-20. 



/f 



52 



TM 5-3805-210-10/TO 36C9-2-16 1 




v" "% /if/ , ' ;"/, 

""^^ '-^ 



Figure 15. Operator's daily services. 



TM 5-3805-210-10/TO 36C9-2-16-1 



Section IV. TROUBLESHOOTING 



34. General 

This section provides information useful in 
diagnosing and correcting unsatisfactory opera- 
tion or failure of the road grader and its com- 
ponents. Each trouble -symptom stated is 
followed by a list of probable causes of the 
trouble. The possible remedy recommended is 
described opposite the probable cause. Any op- 
erational trouble beyond the scope of the op- 
erator or crew shall be reported to organiza- 
tional maintenance. 

35. Engine Hard to Start or Fails to Start 

Probable cause Possible remedy 

Fuel filters clogged Service fuel filters (pars. 

57 and 58). 

Water in fuel system Drain the fuel system (par. 

55) and service fuel fil- 
ters (pars. 57 and 58). 

No fuel pressure Report to organizational 

maintenance. 

Throttle not in starting Position throttle correctly 
position. (par. ,13). 

Air in fuel system Tighten fuel lines on suc- 
tion side of fuel pump 
and fuel filters (pars. 
57 and 58). 

36. Engine Misses or Runs Erratically 

Probable cause Possible remedy 

Water in fuel system Drain the fuel tank '(par. 

55) and service fuel fil- 
ters (pars. 57 and!5'8). 

Defective injectors Report to organizational 

maintenance. 

37. Engine Stops Suddenly 

Probable cause Possible remedy 

Fuel tank empty Fill fuel tank (par. 55). 

Fuel filters clogged Service fuel filters (pars. 

57 and 58)'. 

Water in fuel system Drain fuel tank (par. 55) 

and service fuel filters 
(pars. 57 and 58). 

38. Engine Lacks Power 

Probable cause Possible remedy 

Air cleaner clogged Service air cleaner (par. 

81). 
Fuel filters clogged Service fuel filters (pars. 

57 and 58). 



39. Engine Has Low or No Oil Pressure 



Probable cause 
Oil supply in crankcase 

low. 
Crankcase oil diluted with 

fuel oil. 



Possible remedy 
Refill crankcase (LO 5- 

3805-210-20). 
Report to organizational 

maintenance 



40. Excessive Engine Oil Consumption 

Probable cause Possible remedy 

Engine oil level too high Drain crankcase to proper 

level (LO 5-3805-210- 
20). 

Oil lines leaking Tighten connections. Report 

a broken line to organi- 
zational maintenance. 



41. Engine Overheats 

Probable cause 

Coolant level low 



Radiator clogged 

Radiator core external 

surface dirty. 

Radiator shutter closed 
Fan belt slipping 



Possible remedy 
.Fill cooling system (par. 

60). 

Flush cooling system. 
Remove dirt and foreign 

material from core. 
.Open shutter (par. 13)'. 
.Adjust fan belt (par. .61). 



42. Engine Exhaust Smoky 

Probable cause Possible remedy 

Air cleaner dirty Service air cleaner (par. 

31). 
Excessive oil in crankcase 



Too much oil in air 
cleaner. 



Drain crankcase to proper 
level (LO 5-3805-210- 
20). 

Service air cleaner (par. 
31). 



43. Hydraulic Brakes Do Not Hold 



Probable cause 
Fluid low in master 

cylinder. 
Fluid leaks in hydraulic 

lines. 



Brakes out of adjustment 



Possible remedy 
Fill the master cylinder 

(LO 5-3805-210-20). 
Tighten connecting nuts. 
Report broken lines to 
organizational mainte- 
nance. 
-.Adjust brakes (par. 74). 



44. Hydraulic Controls Inoperative 

Probable cause Possible remedy 

Hydraulic oil supply low Fill hydraulic tank (LO 5-v 

380(5-210-20'). 

Hydraulic oil strainer Service hydraulic oil 

clogged. strainer (par. 76)'. 



54 



TM 5-3805-21 0-1 0/TO 36C9-2-16-1 



45. Blade Will Not Cut 

Probable cause Possible remedy 

Moldboard cutting edge Replace cutting edge (par. 

worn. 83). 

End bits worn Replace end bits (par. 83). 

Moldboard improperly Adjust moldboard (par. 

adjusted. 84). 

Ground too hard Use scarifier (par. 15). 

46. Scarifier Vibrates, Chatters, or Will 
Not Cut 



Possible remedy 
Tighten bolts. 



Probable cause 
Bolts loose in scarifier 

block. 
Scarifier improperly ad- Adjust scarifier (par. 80). 

justed. 
Scarifier teeth worn Replace teeth (par. 81). 



47. Engine Coolant Heater .Inoperative 

Probable cause Possible remedy 

Fuel tank empty Fill fuel tank (par. 55). 

Fuel filter clogged Service fuel filter (par. 

87)i. 

48. Personnel Space Heater Inoperative 

Probable cause Possible remedy 

Fuel tank empty Fill fuel tank '(par. 55). 

Fuel filter clogged Service fuel filter (par. 

87). 

49. Battery Heater Inoperative 

Probable cause Possible remedy 

Fuel tank empty Fill fuel tank (par. 55). 

Fuel filter clogged Service fuel filter (par. 

87). 



Section V. FIELD EXPEDIENT REPAIRS 



50. Field Expedient Repairs 

Operational troubles may occur while the 
road grader is operating in the field where 
supplies and repair parts are not available and 
normal corrective action cannot be performed. 
When this condition exists, the following ex- 
pedant remedies may be used during emergen- 
cies, upon the decision of the unit commander. 
Equipment so repaired must .be removed from 
operation as soon as possible and properly re- 
pafred before being placed in operation again. 

S'l . Engine Lacks Power 

Trouble Expedient remedy 

Fuel filters clogged Remove elements and oper- 
ate without them uritil 
new ones can be obtained 
(pars. 57 and 58). 



52. Engine Oil Pressure Above Normal 



Trouble 

Oil fitter elements 
clogged. 



Expedient remedy 
Remove elements and ope* 
ate without them until 
new ones can be obtainec 
(par. 31). 



53. Engine Fails To Start 



Trouble 

Fuel line or hose cracked 
or broken. 



Expedient remedy 
Wrap fuel line with tape 
and operate until line 
can be obtained. 



Section VI. FUEL SYSTEM 



54. General 

This sc ;tion contains maintenance proce- 
dures for the components of the engine fuel 
system for which the operator is responsible. 
These are the fuel tank, fuel tank strainer, and 
fuel filters. 



55. Fuel Tank Service 

Service the diesel fuel tank as instructed on 
figure 16. 

56. Fuel Tank Strainer Service 

Service the fuel tank strainer as instructed 
on figure 17. 



TM 5-3805-2 10-10/TO 36C9-2-16-1 







tf'. 



r 








L. 



L 



It' i 



AFuel tank 



56 



B Fuel tank drain 



Figure 16. Diesel engine fuel tank service. 



TM 5-3805-21 0-1 0/TO 36C9~2-16~1 



l^/^Vi4W " 

^, F^^^V!^; 71 /^* f 







^ f 

;# 

%, 
# 

t 
t 



I 




*w-|' <'*< / 

v$:<{f&*& 

I** > iL-wJ 




Figure 17. Fuel tank strainer service. 

57. Primary Fuel Filter Service 

Service the primary fuel filter as instructed 
on figure 18. 



58. Secondary Fuel Filter Service 

Service the secondary fuel filter as instructed 
on figure 19. 



Figure IS. Primary fuel filter service. 



TM 5-3805-21 0-10/TO 36C9-2-16-! 



1. SHUT OFF FUEL AT 

BOTTOM OF FUEL TANK. 

3. LOOSEN CENTER BOLT IN TOP 
OF FILTER HOOD. 



YA! \ 

5. REMOVE ELCMEN1 




\L OPEN PI' A IN' ('<' K / ' 
I i/f I M . 1 i ' . 



7. CLEAN SHEEL WITH AN 
APPROVED CLEANING 
SOLVENT AND INSTALL 
WITH NEW ELEMENT 
AND GASKET. 

8. CLOSE DRAfNCOCK AND 
OPEN FUEL TANK' VALVE. 
RUN ENGINE FIVE MINUTES 
AND INSPECT FOR LEAKS 
AROUND FILTER. 



EMC 3805-210-10^9 



Figure 19. Secondary fuel filter service. 



58 



L START AND RUN ENGINE UNTIL 
IT REACHES OPERATING TEM- 
PERATURE 160- 180. 



TM 5-3805-210-1 0/TO 36C9-2-16-1 
Section VII. COOLING SYSTEM 

59. General 

This section describes the maintenance pro- 
cedures and service of the cooling system for 
which the operator is responsible. These are 
the radiator and fan belts. 

60. Radiator Service 

Service the radiator as instructed on figure 
20. 

61 . Fan Belt Adjustment 

Adjust the fan belts as instructed on figure 
21. 



2, SHUT OFF FNGINE, 



3. SLOWLY REMOVE 
RADIATOR CAP. 






RAD) A1 OP SHUT FER 




' THE'PMOSTAl Hf'llfiNi. 







A Radiator cap 

B Thermostat housing dram 

Figure 20. Radiator service. 



59 



TM 5-3805-210-10/TO 36C9-2-16-1 



C NOTE: -FM j. cCOt.NG VrSlLV HAS DRA>ET, CLOSI- *M V '. ?jr< rS/U< 

F'lL ClTVNG cv ^ T cV j * :- CLf 'N l */TtP /''-I *N /uK* l '~'/t" Ml, HS 
SCLUTJCN. PIN ENG'NE FOR 30 MiNUT L5 /*ND D^Mifi CC ul iNu C M M t f/ 
ADD ^N APPROVED NfUTFAlPlNG AC* NT AND F'lL COollNG SfSii// 
A'TH CLEAN AA1EF OR A.^i Frn I 7t SOLU 




c 



60 



C Cooling system drain 
Figure 20 Continued. 



TM 5-3805-210-10/10 36C9-2-16- 



(3) 



FRY ADJUSTING 
BRACKET UP UNTIL 
THERE IS 1/2 INCH 
DEFLECTION OH 
BELT'S WHEN PUSHED 
IN MIDWAY BETWEEN 
PULLEYS AND TIGHTEN 
BOLTS. 



_ , 
FAN BELT (2) 




belt adjustment. 



TM 5-3805-210-10/TO 36C9-2-16-1 



Section VIII. ELECTRICAL SYSTEM 



62. General 

This section describes the maintenance pro- 
cedures and service of the electrical system 
which are the responsibility of the operator. 
These are the generator drive belts, batteries, 
instrument panel and trouble light lamps. 

63. Generator Drive Belt Adjustment 

Adjust the generator drive belt .as instructed 
on figure 22. 

64. Battery Service 

Service the batteries as instructed on figure 
23. 



65, Instrument Panel Lamp Replacement 

a. Removal. Remove the instrument panel 
lamp as instructed on figure 24. 

6. Installation. Install the instrument panel 
lamp in reverse of the instructions on figure 
24. 

66. Trouble Light Lamp 

a. Removal. Press in on the lamp and turn 
it clockwise ui^til it releases from the socket. 

b. Installation- Press a new bulb into the 
socket and turn it clockwise until it is locked 
in the socket. 



TM 5-3805-21 0-10/TO 36C9--2-16-1 







1, LOOSEN CAPSCREW. 



JL'-^'.NG B9ACKET. 



3. PULL GENERATOR AWAY FROM 
ENGINE UNTIL BELTS HAVE 1/2 
INCH DEFLECTION MIDWAY BETWEEN 
PULLEYS AND TIGHTEN CAPSCREW 
AND BOLTS. 

" !TT'-t - 



, DEFLECTION 



GENERATOR 



DRIVE- BELTS 



EMC 3805-21D-1U ' 




Figure 22. Generator drive belt adjustment. 



TM 5-3805-210-10/TO 36C9-2-16-1 



I. REMOVE BATTERS 



\r 



BOX COVER (21 



.3, FILi LACH Cm WITH DISTILLED WATER UNTIL 
! f LtCTROLYTt IS 3'8 IN, ABOVE THE PLATES, , 



12. REMOVE FILLER CAP (24 



1 4. INS1/LL FILLER CAPS. 




STAPTF.P-TO-BATTERY LEAD 



CAUTION: IN F^FEZING 



FOR AT 

{ '! f Cl^OlYTE, 




Figure 23. Battery service. 



64 



TM 5-3805-2 10- 1 0/TO 36C9-2-16-1 



IKMNG C('UMcK 
CLCCKMSt, 

/ 




Figure 24- Instrument panel lamp replacement. 

Section IX. CLUTCH RELEASE MECHANISM AND BRAKE 



67. General 

The clutch release mechanism transmits 
pressure applied on the clutch pedal to the 
clutch linkage. A common linkage applies the 
clutch brake which stops, the transmission 
gears from turning, allowing the operator to 
shift the transmission gecvrs into various speed 
ranges. 



68. Clutch Release Mechanism Adjustment 

Adjust the clutch release mechanism as in- 
structed on figure 25. 

69. Clutch Brake Adjustment 

Adjust the clutch brake as instructed on fig- 
ure 26. 



TM S-3805-210-10/TO 36C9-2-16-1 



NOTE- THERE SHOULD BE SIX AND ONE-HALF INCHES OF 

TRAVEL FOR COMPLETE DISENGAGEMENT OF CLUTCH 
AND ENGAGEMENT OF CLUTCH BRAKE. 




3 ADJUST CLEVISES UNTIL CLUTCH 
blSENGAGES WITH PEDAL STOP 
3 INCHES FROM FLOOR PLATE. 





LOOSEN LOCKNUT (1.21). 



NOTE- AS CLUTCH FACINGS WEAR, THE FREE MOVEMENT 
N DECREASES AND ADJUSTMENTS SHOULD BE MADE 

BEFORE THIS DIMENSION HAS BECOME LESS 

THAN TWO INCHES MINIMUM. 



EMC 3805-210-10/25 



Figure 25. Clutch release mechanism adjustment. 



TM 5-3805-2 10-10/TO 36C9-2-16-1 



WITH CLUTCH PEDAL FULLY 
DEPRESSED TURN ADJUSTING 
NUT UNTIL THE SPRINGS 
COMPRESSED TO 11/16 INCH. 
TIGHTEN LOCKNUT. 



I. LOOSEN LOCKNUT 






DEPRESSED TURN ADJUSTING 
NUT UNTIL THE SPRING IS 
COMPRESSED TO 1-13/16 
INCH. TIGHTEN LOCKNUT 



1. LOOSEN LOCKNUT 




B 



EMC 3805-210-10/26 



A Clutch brake adjustment (Serial rang-e MD-101 through MD^-971) 
B Clutch brake adjustment (Serial range MD-972 through MD-1107) 

Figure 26. Clutch brake adjustment. 



67 



TM 5-3805-2 10- TO/TO 36C9-2-16-1 

Section X. HANDBRAKE 



70. General 

The handbrake lever is located in the oper- 
ator s cab to the left of the steering wheel. 
The handbrake lever is used to engage the ure2.7. 
grader brakes when the grader is parked or 
not in operation. 



71. Handbrake Adjustment 

Adjugt ^ handbrake ta instr ucted on fig- 



r 



\ 




-. x 



/ ' ^i $ 




Figure 27. Handbrake adjustment. 

Section XL SERVICE BRAKE SYSTEM 

72. General 73. Master Cylinder Service 

The grader service brake system is hydrauli- Seryice the master cylinder ^ instructed on 
cally operated. It consists of a master cylinder, figure 28 
wheel cylinders, and lines and fittings neces- 
sary to complete the system. Foot pressure - A . D ... 
applied to the pedal transmits hydraulic fluid 74 ' Servlce Bmke Ad l stme n 
from the master cylinder to the wheel cylinders Adjust the service brakes as instructed on 
which in turn actuate the brakeshoes. figure 29. 



68 



TM 5-3805-2 10-10/TO 36C9-2-16-1 



1 



Figure 28. Master cylinder service. 



Figure 29. Service brake adjustment. 69 



TM 5-3805-2 10-10/TO 36C9-2-16-1 

Section XII. HYDRAULIC SYSTEM 

75. General 76. Hydraulic Took and Strainer Service 

This section describes the maintenance and 



c and 

service procedures on the hydraulic system J 

which are the responsibility of the operator. structed on figure 30. 
These are the hydraulic tank and strainer. 



70 



TM 5-3805-21 0-1 0/TO 36C9-2-16-1 



Kfc'MUVL DRAIN PI ' 
DRAIN HYDFAUIJC 

IN A sun AM F CUM AIM; 






A Hydraulic tank drain 

B Hydraulic tank 
C Hydraulic oil strainer 

Figure 30. Hydraulic tank and strainer service. 



71 



TM 5-3805-2 1Q--10/7O 36C9-2-16-1 

Section XIII. WINDSHIELD WIPER ASSEMBLIES 

77. General 

This section describes the maintenance and 
service procedures on the windshield wiper as- 
semblies which are the responsibility of the 
operator 

78. Windshield Wiper Blade Replacement 

a. Removal. Remove the windshield wiper 
blades as instructed on figure 31. 

&. Installation. Install the windshield wiper 
blades in reverse of the instructions on figure 
81. 



WINDSHIELD 
WIPER ARM 



WIPER 
MOTOR 



7. REMOVE BLADE* 

I-- 



WINDSHIELD WIPER BLADE 




EMC 3805 -2 10- 10/31 



Figure 31. Windshield wiper blade, removal and 
installation. 



Section XIV. SCARIFIER ASSEMBLY 



79. General 

The scarifier assembly is located behind the 
front axle of the grader. It consists of a scari- 
fier block and 11 removable teeth. The scari- 
fier is used to tear up material which is too 
hard to cut with the blade. 

80. Scarifier Adjustment 

Adjust the scarifier as instructed on figure 
32. 



81 . Scarifier Teeth Replacement 

a. Removal. Remove :the scarifier teetn as 
instructed on figure 33. 

b. Installation, Install the scarifier teeth in 
reverse of the instructions on figure 33. 



TM 5 3805-210-10/TO 36C9-2-16-1 



I' fh 

rr ' 



TOOTH nn 




1 TILT SCARIFIER 10 
HOLES NEAREST 
ANQLE AND INSTALL 



MCLDBGARD 



f 

' 27 REMOVE TOOTH 




EMC 3S05-210-VO/32. 



3. 

L 

4 """INSTALL "NEW 

^ AS 



Figure 82. Scarifier adjustment. 



Figure 33. Scarifier teeth replacement. 



Section XV. MOLDBQARD ASSEMBLY 



82. Genera! 



The moldboard assembly is located behind 
the scarifier assembly and below the circle turn 
Assembly. It is 12 feet long and consists of 
moldboard, a cutting blade, and two sets of 
end bits. The blade is mounted on the lower 
edge of the moldboard and is the cutting edge 
used in grading. The end bits are located, on 
each end of the moldboard and used in ditch- 
ing operations. 



83. Moldboard Cutting Blade and End 
Bit Replacement 

a. Removal. Remove the cutting blade and 
end bits as instructed on figure 34. 

b. Installation. Install the cutting blade and 
end bits in reverse of the instructions on fig- 
ure 34. 



84. Moldboard Tilt Adjustment 

Adjust the moldboard tilt setting as 
structed on figure 35. 



m- 



IM 5-3805-21 0-1 0/TO 36C9-2-16-1 



2. REMOVE BOLT (24) 
RAISE THF J/OLDBQARD. 



4. REMOVE END BIT (2) 
' 




3. REMOVE CUTTING EDGE 



EMC 3805-210-10/34 



Figure 34. Moldboard cutting blade and end bit, removal and installation. 



TM 5-3805-2 10-10/TO 36C9-2--16-.1 



II. THE 




3. TILT MOLDBOARD TO 

DESIRED POSITION AND 
TIGHTEN NUTS, 



CUTTING 
EDGE 



EMC 3805-210-10/35 



Figure 35. Moldboard tilt adjustment. 



TM 5-3805-210-1 0/TO 36C9-2-16-1 

Section XVI. WINTfeRlZATION EQUIPMENT 

85. General 86. Heater Fuel Pump Service 

Service the heater fuel pipnps as instructed 
This section describes the maintenance pro- on f . ^ 3g 
cedures and service of the winterization equip- 
ment which are the responsibility of the opera- 87. Heater Fuel Filter Service 
tor. These are the heater fuel pumps and Service the heater fuel filters as instructed on 



filters. 



figure 37. 




':,:(.'.. 210 1C 36 



Figure 36. Heater fuel pump service. 



TM 5-3805-2 10-10/TO 36C9-2-1 6-1 




. , . , [ !L7t"W ELEMENT AND SHELL IN Mi 
" cXfA^jo^O^^^ 



Figure 37. Heater fuel filter service. 



TM 5-3805-2 10-10/TO 36C9-2-16-1 



CHAPTER 4 

DEMOLITION OF MATERIEL TO PREVENT ENEMY USE 



88. General 

When capture or abandonment of the grader 
to an enemy is imminent, the responsible unit 
commander must make the decision either to 
destroy the equipment or to render it inopera- 
tive. Based on this decision, orders are issued 
which cover the desired extent of destruction. 
Whatever method of demolition is employed, it 
is essential to destroy the same vital parts of 
all graders and all corresponding repair parts. 

89. Demolition to Render The Engine 
Inoperative 

a. Demolition by Mechanical Means. Use 
sledge hammers, crow-bars, picks, axes, or any 
other heavy tools which may be available to 
destroy the following: 

(1) Engine block and manifold. 

(2) Governor and water pump. 

(3) Radiator, starter motor, and genera- 
tor. 

Note. The above steps are minimum re- 
quirements for this method. 

(4) Instrument panel, hydraulic controls, 
steering gear assembly, 

b. Demolition by Misuse. Perform the fol- 
lowing to render the engine inoperative. 

(1) Drain radiator and engine crankcase. 
Put sand, gravel, nuts, bolts, screws, 
or broken glass in the crankcase and 
operate engine on f ujl throttle until 
failure occurs. 

(2) Disconnect radiator fan and . run en- 
gine at full throttle for piston and 
ring seizure. 

Note. (1) and (2) above are minimum 
requirements for this method. 

90. Demolition by Explosives or Weapons Fire 

a. Explosives. Place as many of the follow- 
ing charges (fig. 38) as the situation permits 
and detonate them simultaneously with det- 
onating cord and a suitable detonator. 



(1) Two 1/2-pound charges behind 
starter on side of engine block. 

(2) Two 1/2-pound charges on each tan- 
dem drive case. 

Note. The above charges are the minimum 
requirements for this method. 

(3) Two 1/2-pound charges under steer- 
ing gear housing. 

6. Weapons Fire. Fire on the grader with 
the heaviest practical weapons available. 

91. Other Demolition Methods 

a. Scattering and Concealment. Remove all 
easily accessible parts such as the fuel transfer 
pump, governor, generator, and starter motor. 
Scatter them through dense foliage, bury them 
in dirt or sand, or throw them in a lake, 
stream, or other body of water. 

6. Burning. Pack rags, clothing, or canvas 
under, around, and inside the grader. Saturate 
this packing with gasoline, oil, or diesel fuel 
and ignite. 

c. Submersion. Totally submerge the grader 
in a body of water to provide water damage 
and concealment. Salt water will damage metal 
parts more than fresh water. 

92. Training 

All operators should receive thorough train- 
ing in the destruction of the grader. Refer to 
FM 5-25. Simulated destruction, using all the 
methods listed above, should be included in 
the operator training program. It must be 
emphasized in training that demolition oper- 
ations are usually necessitated by critical situa- 
tions when time available for carrying out de- 
struction is limited. For this reason, it is neces- 
sary that operators be thoroughly familiar with 
all methods of destruction of equipment and 
be able to carry out demolition instructions 
without reference to this or any other manual. 



TM 5-3805-210-10/TO 36C9-2-16~] 



TWO -1/2 POUND CHARGES 
ON EACH TANDEM 
DRIVE CASE 




TWO* 1/2 POUND CHARGES 
UNDER STEERING 
GEAR HOUSING 



TWO -1/2 POUND CHARGES 
BEHIND STARTER ON 
SIDE OF ENGINE BLOCK 



LEGEND: l/2 POUND CHARGE 



EMC 3805-210-10/38 



Figure 38. Placement of charges. 



80 



TM 5-3805-2 10-10/TO 36C9 2-16-1 



APPENDIX I 
REFERENCES 



1 . Dictionaries of Terms and Abbreviations 

AR 320-5 Dictionary of United States Army Terms 

AR 320-50 Authorized Abbreviations and Brevity Codes 

2. Fire Protection 

TM 5-687 Repairs and Utilities : Fire Protection Equipment and Appliances ; Inspec- 

tions, Operations, and Preventive Maintenance 
TM 9-1799 Ordnance Maintenance : Fire Extinguishers 

3. Lubrication 

LO 5-3805-210- Grader, Road, Motorized: Diesel Driven; 12,100 to 14,300 Ib Pressure at 
20 Blade; (Huber-WARCO Model 4D) 

4. Painting 

TB ENG-60 Preservation and Painting of Serviceable Corps of Engineers Equipment 

5. Preventive Maintenance 

AR 750-5 Organization, Policies, and Responsibilities for Maintenance Operation 

TB ENG 347 Winterization Techniques for Engineer Equipment 

TM 9-1870-1 Care and Maintenance of Pneumatic Tires 

TM 9-6140-200- Operation and Organizational, Field, and Depot Maintenance: Storage 

15 Batteries, Lead-acid Type 

TM 38-750 The Army Equipment Records System and Procedures 

6. Publication Indexes 

DA Pam 310-4 Index of Technical Manuals, Technical Bulletins, Supply Bulletins, Lu- 
brication Orders, and Modification Work Orders 

7. Supply Publications 

SM 10-1-C4-1 Petroleum, Petroleum-Base Products, and Related Material 

8. Training Aids 

FM 5-25 Explosives and Demolitions 



TM 5-3S05-210-10/TO 36C9-2-U-1 



APPENDIX II 
BASIC ISSUE ITEMS LIST 



Section 1, INTRODUCTION 



1. General 

This appendix lists the accessories, took, and 
publications required in 1st echelon mainte- 
nance and operation, initially issued with, or 
authorized for, the grader. 

2. Explanation el Columns 

OH Source Codes. The information provided 
in each column is as follows : 

(1) Technical service, This column lists 
the basic number of the technical 
service assigned supply responsibility 
for the part, The blank spaces de- 
note Corps of Engineers supply re- 
sponsibility. General Engineer sup- 
ply parts are identified by the letters 
"GE" in parentheses, following the 
nomenclature in the description col- 
umn. Other technical services basic 
numbers are: 

8 Chemical Corps 

9 Ordnance Corps 
10 Quartermaster Corps 
12 Adjutant General's Corps 

(2) Source. The selection status and 
source of supply for each part are in- 
dicated by one of the following code 
symbols: 

(a) P applied to high-mortality repair 
parts which are stocked in or sup- 
plied from the technical service de- 
pot system, and authorized for 
use at indicated maintenance eche- 
lons. 

(&) PI applied to repair parts which 
are low-mortality parts, stocked in 
or supplied from technical service 
depots, and authorized for installa- 



tion at indicated maintenance eche* 
Ions. 

(8) Maintenance. The lowest mainte- 
nance echelon authorized to use, 
stock, install, or manufacture the 
part is indicated by the following code 
symbol: 
Organizational Maintenance 

(1st 'and 2d Echelon) 
6. Federal Stock Numbers. When a Federal 
atock number is available for a part, it will be 
shown in this column And used for requisition- 
ing purposes, 
o. Description. 

(1) The item name and a brief descrip- 
tion of the part are shown. 

(2) The letters "GE", shown in parenthe- 
ses immediately following the de- 
scription indicate General Engineer 
supply responsibility for the part. 

d. Unit of Issue. Where no abbreviation is 
shown in this column, the unit of issue is 
"each". 

e. ExpendabUity. Those items classified as 
nonexpendable are indicated by letters "NX". 
Items not indicated by "NX" are expendable. 

/. Quantity Authorized. This column lists 
the quantities of repair parts, accessories, tools, 
or publications authorized for issue to the 
equipment operator or crew as required. 

g. Quantity Issued With Equipment. This 
column lists the quantities of repair parts, ac- 
cessories, tools, or publications that are initial- 
ly issued with each item of equipment. Those 
indicated by an asterisk are to be requisitioned 
through normal supply channels as required. 

h. Illustrations. This column is subdivided 
into two columns which provide the following 
information : 



TM 5-3805-2 10-10/TO 36C9-2-16-1 



(1) Figure number. Provides the identi- 
fying number of the illustration. 

(2) Item number. Provides the refer- 
enced number for' the part shown in 
the illustration. 

3. Comments and Suggestions 

Suggestions and recommendations for 



changes to the Basic Issue Items List shall 
be submitted on DA Form 2028 to the Com- 
manding Officer, U.S. Army Engineer Mainte- 
nance Center, ATTN: EMCDM-S, P.O. Box 
119, Columbus 16, Ohio. Direct communica- 
tion is authorized. 







10 




1 Ball-peen hammer 

2 Adjustabl wrench 

3 Ether cartridge 

4 Grease gun 

5 Oil can 

6 Grease hose 





EMC Od05-2 10-10/39 



7 Lamp 

8 Open end wrench 

9 Extension light 

10 Tire gage 

11 Screwdriver 

12 Slip joint pliers 

Figure 39. Basic issue items. 



84 



TM 5-3805-21 0-10/TO 36C9-2-16-1 
Section II. BASIC ISSUE ITEMS LIST 



Source codes 


Federal 
stock 
No. 


Description 


^ 
| 


Expendability 1 


Quantity 
authorized 


Quantity issued I 
with equipment I 


Illustration 


1 Technical 1 
service 




1 


Maintenance 
Reenterability 


Fis. 


Item 










GROUP 06 






















ELECTEICAL SYSTEM 






















(ENGINE AND VEHICULAR) 






















0612 BATTERIES 














$ 


PI 





6140-057-2654 


BATTERY, STORAGE: 12 volt; 100 amp 




NX 


4 


4 














(Specify Willard or Exide batteries when 






















ordering: for winterized units.) 














8 


p 





6810^264-9063 


SULPHURIC ACID: electrolyte. 






















GROUP 26 ACCESSORIES, 


Gal 




7 


7 














PUBLICATIONS, TEST EQUIPMENT 






















AND TOOLS 






















2602.1 ACCESSORIES 














10 


p 





7520-659-9618 


CASE: operation and maintenance publi- 






1 


1 














cations, cotton duck, water repellent and 






















mildew resistant MIL-B-11743-B. 
















PI 





2910-355-6377 


PRESSURE PRIMER: diesel engine (GE) 






1 


* 


39 


3 










(Winterized Units). 
















p 


o 


6240-456-7705 


LAMP, INCANDESCENT: 28 V, 15 CP, 






1 


* 


39 


7 










No. 306 clear. 
















PI 





6230-268-9435 


LIGHT, EXTENSION: 2 conductor cable, 






1 


* 


39 


9 










12 ft long. 






















2602.2 COMMON TOOLS 














10 


PI 





61i20-224-4046 


HAMMER, HAND: machinist ball-peen; 20 






1 


* 


39 


1 










oz; head weight. 














10 


PI 





5120^264-3796 


WRENCH, OPEN END, ADJUSTABLE: 






1 


* 


39 


2 










single head type; to 1.322 in. jaw open-^ 






















ing; 12 in. long. 














10 


PI 





4930-360-2801 


GREASE GUN, HAND: lever operated, 






1 


* 


39 


4 










16 oz capacity; extension, 7 in. long and 






















hydraulic coupler MIL-G-3859. 














10 


PI 





493)0-430-3264 


HOSE, GREASE: 20 in. long 






1 


* 


39 


6 


9 


PI 





4910-261-S408 


GAGE, TIRE PRESSURE, SELF-CON- 






1 


* 


39 


10 










TAINED: 10 Ib to 160 Ib range, 12KL/2 






















in. long. 














10 


Bl 





5120-223-7396 


PLIERS, SLIP JOINT: straight hose type, 






1 


* 


39 


12, 










combination w/cutters; 6 in. long. 














10 


PI 





4930-168-3264 


OILER, HAND: 8 oz capacity, force fed. 






1 


* 


39 


5 


10 


PI 





6120H23O-3675 


SCREWDRIVER, FLAT TIP: 1/4 in. 






1 


# 


39 


11 










width tip ; 6 in. long. 














10 


PI 





5120-277-9818 


WRENCH, OPEN END, FIXED: double 






1 


* 


39 


8 










head type; 1-1/2 in. and 1-3/4 in. open- 






















ings; 16-1/2 in. long. 















TM 5-3805-2 10-10/TO 36C9-2-16-1 



Sotaree eodes 
















Illuetrfttioa 




Federal 


























Detorfrtion 


j 




. 


]j 








)i 


i 










| 




i] 


8 




Vis. 


Ztea 


12 










2602.4 PUBLICATIONS 
DEPARTMENT OP THE ARMY OPER- 






t 


2 


















ATORS MANUAL TM '5-3805-210-40 
















12 










DEPARTMENT OP THE ARMY ORGA- 






3 


2 
















NIZATIONAL MAINTENANCE MAN- 


























UAL TM 5-8805-210-20 
















12 










DEPARTMENT OP THE ARMY ORGA- 






ig 


2 
















NIZATIONAL MAINTENANCE RE- 


























PAIR PARTS AND SPECIAL TOOL 


























LIST TM 5-^805-210-20P 
















12 










DEPARTMENT OP THE ARMY LU- 






1 


1 


















BRICATION ORDER LO 5-8805-210-20 


























GROUP 7$ 


























PIREPIGHTING EQUIPMENT 


























7*08 FIRE EXTINGUISHERS 


















PI 







4810*228-9915 


EXTINGUISHER, FIRE, CARBON DI- 






(SEE 


NOTE) 














OXIDE: ltd charged; hand; fihatterable 


























cylinder; permanent ahutoff valve. 


















PI 







4210-565-8837 


EXTINGUISHER, PIRE MJONOBROMO- 






1 


* 


















TRIPLUOROMETHANE : charged, 


























hand-0hatterable cylinder, penetrating 


























eal valve, stored preaaura, w/bracket, 


























2.75 Ibs (Harlon-1801) Mil Spec E- 


























52081. (GE) 


























Note* Requisition carbon dioxide extlnguiiner un- 


























til Depot stock* are exhausted. ' 

















TM 5-3805-21 0-1 0/TO 36C9-2- 6-1 



INDEX 



Paragraph Page 

Adjustment: 

Clutch brake 69 65 

Clutch release mechanism ; 68 66 

Fan belt - - - _____.._.. ._ ... -* . 61 59 

Generator drive belt 63 62 

Handbrake 71 68 

Moldboard tilt ^ . 84 73 

Scarifier 80 72 

Service brake - - . ... .- 74 68 

Battery service 64 62 

Basic issue tools and equipment 29 35 

Brake system, service 72 68 

Clutch brake adjustment 69 65 

Clutch release mechanism adjustment 68 65 

Controls and instruments 11 11 

Daily maintenance service and inspection procedures 33 61 

Data, tabulated 4 3 

Demolition: 

Burning 916 79 

Explosives - 90a 79 

Explosives or weapons fire 90 79 

Mechanical means 89a 79 

Misuse _ 896 79 

Scattering and concealment 91a 79 

Submersion 91c 79 

Weapons fire 906 79 

Description, equipment - -. 3 3 

Detailed lubrication information 31 36 

Difference in models 5 10 

Dusty areas, operation , 18 20 

Equipment: 

Basic issue 29 36 

Operation 12 20 

Special 28 35 

Ether starting aids 26 32 

Extinguisher, fire 22, 23 31 

Extreme cold, operation 16 20 

Extreme heat, operation 17 20 

Fan belt adjustment 61 59 

Field expedient repairs 60 56 

Engine fails to start 63 55 

Engine lacks power 51 56 

Engine oil pressure above normal 52 55 

Fire extinguisher, carbon dioxide type 23 31 

Fire extinguisher, monobrpmotrifluoromethane type 22 31 

Forms, record and report - 2 3 

Fuel tank service, diesel engine 55 56 

Fuel tank strainer service 56 56 

Generator drive adjustment 63 62 

Handbrake adjustment 71 68 

Heaters 25 32 

Heater fuel filter service 87 .76 



TM 5-3805-21 0-10/TO 36C9-2-16-! 

Paragraph pag IF] ' 

Heater fuel pump service 86 78 

High altitude operation . 21 31 

Humid conditions, operation 19 20 

Hydraulic oil strainer 76 70 

Hydraulic tank and strainer service 76 70 

Identification and tabulated data 4 8 

Inspecting and servicing the road grader 7 11 

Inspecting, road grader 7 11 

Installation or setting-up instructions . 8 11 

Instrument panel lamp replacement 65 62 

Lamp, trouble light 66 62 

Light, trouble -^ 27 34 

Lubrication information: 

Detailed ^ ---*. 31 35 

General . 30 35 

Master cylinder service 73 68 

Maintenance inspection procedures, daily 33 61 

Maintenance, preventive , 32 51 

Maintenance service procedures, daily 33 51 

Mechanism, clutch release and brake 67 65 

Models, difference - ~ - 5 10 

Moldboard cutting blade and end bit replacement 83 73 

Moldboard tilt adjustment - 84 73 

Movement to a new work site 9 11 

New work site, movement 9 11 

Oil strainer, hydraulic. 76 70 ^* 

Operation: 

Dusty or sandy areas 18 20 

Extreme cold (below 0F.) 16 20 

Extreme heat 17 20 

High altitudes - 21 31 

Rainy or humid conditions 19 20 

Road grader . 15 20 

Salt water areas , 20 31 

Other demolition methods 91 79 

Preventive maintenance 32 61 

Primary and secondary oil filter service 31, 35 

Primary fuel filter service 57 57 

Radiator service 60 59 

Rainy conditions, operation 19 20 

Record and report forms 2 3 

Repairs, field expedient _ : .. 50 55 

Road grader engine: 

Starting , , 13 20 

Stopping . ..... 14 20 

Road grader operatipn 15 20 

Road grader, unloading 6 11 

Salt water areas, operation 20 31 

Sandy areas, operation 18 20 

Scarifier adjustment 80 72 

Scarifier teeth replacement . 81 72 

Scope 1 3 

Secondary fuel filter service ! . 58 57 

Service and inspection, during, before, and after operation 336 61 

1r 

98 



TM 5-3805-210-10/TO 36C9-2 16-1 

Paragraph Page 

Service: 

Air cleaner Blh 36 

Battery 64 62 

Brake adjustment . 74 68 

Fuel tank 65 55 

Fuel tank strainer , 66 65 

Heater fuel filter 87 76 

Heater fuel pump 86 76 

Hydraulic tank and strainer 76 70 

Master cylinder 73 68 

Precleaner 31/i 35 

Primary fuel filter 57 57 

Primary oil filter 31/ 36 

Radiator 60 59 

Secondary fuel filter 68 57 

Secondary oil filter 31/ 35 

Road grader 7 11 

Transmission breather 310 35 

Setting-up instructions 8 11 

Slave receptacle 24 32 

Special tools and equipment 28 35 

Starting aids, ether -. , 26 32 

Starting the road grader engine 13 20 

Stopping the road grader engine 14 20 

Tabulated data 4 3 

Tools, basic issue 29 35 

Tools, special 28 36 

Training, destruction of equipment 92 79 

Trouble light 27 34 

Trouble light lamp 66 62 

Troubleshooting : 

Battery heater inoperative 49 66 

Blade will not cut 45 55 

Engine coolant heater inoperative 47 55 

Engine exhaust smoky 42 64 

Engine hard to start or fails 35 64 

Engine has low or no oil pressure 39 64 

Engine lacks power . 38 54 

Engine misses or runs erratically 36 54 

Engine overheats 41 54 

Engine stops suddenly 37 54 

Excessive engine oil consumption 40 54 

Hydraulic brakes do not hold 43 64 

Hydraulic controls inoperative 44 54 

Personnel space heater inoperative 48 56 

Scarifier vibrates, chatters, or will not cut 46 55 

Unloading the road grader 6 11 

Windshield wiper blade replacement 78 72 



?M i-3805--2!0-~10/TO 36C9-2-16-1 

BY OKDER OP THE SECRETARIES OF THE ARMY AND THE AIR FORCE: 



Official: 

J. C. LAMBERT, 
Major General, United States Army, 
The Adjutant General. 

Official: 

R. J. PUGH, 

Colonel, United States Air Force, 
Director of Administrative Services. 

Distribution 

Active Army: 

USASA (2) 

DCSLOG (1) 

CNGB (1) 

Tech Stf, DA (1) except 

CofEngrs (3) 
Army Maint Bd (1) 
USCONARC (3) 
USAARTYBD (2) 
USAARMBD (2) 
USAIB (2) 
USARADBD (2) 

USA Abn, Elct, & SPWAR Bd (2) 
USAAVNBD (2) 
ARADCOM (2) 
ARADCOM Rgn (2) 
OS Maj Comd (5) except 

USASETAF (2) 

USARJ (10) 
MDW (1) 
Armies (2) 
Corps (2) 
Div (2) 
Engr Bde (1) 
Svc Colleges (2) 
Br Svc Sch (2) except 

USAES (100) 
USMA (2) 
GENDEP (2) except 

Schenectady GENDEP (4) 

Atlanta GENDEP (4) 

Utah GENDEP (4) 

Memphis GENDEP (4) 

Sharpe GENDEP (4) 
Engr Sec, GENDEP (10) 
Engr Dep (10) except 

Granite City Engr Dep (14) 
OSA (2) 
Engr Dost (|2) except 

Buffalo Engr Dist (1) 



G. H. DECKER, 

General, United States Army, 

Chief of Staff. 



CURTIS E. LEMAY 

Chief of Staff, United States Air Force. 



Chicago Engr Diet (1) 
Detroit Engr Dist (1) 
Alaska Engr Dist (1) 
Los Angeles Engr Dist (1) 
New Orleans Engr Dist (1) 
New York Engr Dist (1) 
Louisville Engr Dist (1) 
Pittsburgh Engr Dist (1) 
San Francisco Engr Dist (1) 
Omaha Engr Dist (1) 
Seattle Engr Dist (1) 
Kansas City Engr Dist (1) 
Baltimore Engr Dist (1) 
Ft Worth Engr Dist (1) 
Eastern Ocean Engr Dist (1) 
Philadelphia Engr Dist (!) 
Rock Island Engr Dist (1) 
St Louis En^r Dist (1) 
St Paul EngrBist (1) 

Div Engr Dist (2^ except 
Lower Miss Valley Div Engr (none) 
North Central DiV Engr (none) 

Engr Fid Maint Shops (2) 

Engr Dep Maint Shops (2) 

USAERDL (3) 

Engr Cen (6) 

AMS (3) 

USA Engr'Proc Ofc (10) 

EMC (26) 

ESCO (10) 

Fid Comd, DASA (8) 

Def Log Svc Cen (1) 

USACOMZEUR (2) 

USAREUR Engr Sup Con Agcy (10) 

USAREUR Engr Proc Cen (2) 

USA Corps (1) 

MAAG (1) 

JBUSMC (1) 

USA Trans Tml Comd (2) 



Army Tml (2) 

Units org under fol TOE: 

Two copies each UNOINDC: 

5-5 

5-6 

5-15 

5-16 

5-35 

5-36 

5-45 

5-46 

5-48 

5-54 

5-116 

5-117 

5-118 

5-127 

5-145 

5-146 

5-155 

5-166 

5-237 (5) 

5-262 (5) 

5-267 (1) 

5-278 (5) 

5-279 

5-420 

5-425 

5-427 

5-500 (EA, EB, 
HD-HG) 

5-600 

5-625 

5-627 

7-100 

17-100 

37-100 

39-51 

39-61 



NG: State AG (3). 

USAR: Same as active Army except allowance is one copy each unit. 

For explanation of abbreviations used, see AR 320-50. 



90 



*U.S. GOVERNMENT PRINTING OFFICE : 1988 - 201-421 (80169) 



SAFETY PRECAUTIONS 

BEFORE OPERATION 

Exercise care in handling fuel. Do not fill fuel tank with engine 
running. Ground the fuel container to the grader to avoid igniting fuel 
vapors with a static spark. 

Clean excess grease, oil, and spilled fuel from the grader to avoid 
accidents by slipping or falling. 

Do not clean, service, or make adjustments with the engine running 
unless absolutely necessary. 

When inflating tires, stand clear of the lockring to avoid injury if it 
should be forced from the rim. 

Be sure the grader is properly blocked and brakes set when inspecting 
or servicing underneath. 

Do not allow flame or smoking around flammable materials when 
servicing the grader. 

Use caution when filling batteries as electrolyte may cause serious 
burns if spilled on the body. 

DURING OPERATION 

Do not make sharp turns at high speeds. Overturning the grader 
could result in serious injury. 

Do not dismount from the grader without first lowering blade and 
setting brakes. 

Be sure there are no obstructions or personnel in the direction of 
travel before moving grader. 

Do not clean, service, or make adjustments with the engine running 
unless absolutely necessary. 

Keep the transmission and clutch engaged while traveling down steep 
grades to avoid losing control of the grader 

If the grader engine is operated in an inclosed area, pipe the exhaust 
gases to the outside. 

AFTER OPERATION 

Before dismounting from the grader, lower the blade and engage the 
brakes. 

Stop the engine before cleaning, servicing, or adjusting the grader 
unless engine operation is absolutely necessary. 

Clean all excess grease, oil, and spilled fuel from the grader surfaces 
to prevent injury by slipping or falling. 

When inflating tires, stand clear of the lockrings to avoid injury 
should the lockring be forced off. 

Do not allow flame or smoking aroud flammable material while 
servicing the grader. 

Before making adjustments or servicing the underside of the grader, 
provide adequate blocking and engage the brakes. 

Use caution when removing the radiator cap to avoid burns from 

steam.